Customer Projects

Explore in-depth presentations of innovative Ignition® projects submitted by our customers.

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customer project Manufacturing

Global Collaboration Helps Steel Manufacturer Implement Centralized Control Room

The main purpose of Uddeholm, a Voestalpine company, is to manufacture high-quality industrial steel tools, applying best practices for an efficient use of resources and a sustainable development. This strategy has led Uddeholm to become the world’s leading steel tool manufacturer with more than 350 years of innovation and presence in more than 90 countries.

5 min video

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customer project Food and Beverage

All Equipment And Recipes Across 10 Lines Monitored With Single Project

This Ignition project came as a result of a controls-focused project on increasing OEE across 10 packaging lines, specifically monitoring two aspects of production. The first was trending the speeds of each piece of equipment on the line to allow users to monitor the V-Curve over time. The second was maintaining equipment recipe data and tracking when changes were made.

6 min video

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customer project Manufacturing

Glass Company Increases Profitability With True-North Metrics

HMI Glass was facing numerous challenges impacting profitability, leading to reduced earnings before interest, taxes, depreciation, and amortization (EBITDA) since 2018. The scope of the project was to utilize intelligent manufacturing data to implement a lean management model and drive cultural transformation. The success of the project was tied to fees based on performance and utilized a gainshare model based on a cost of poor-quality improvement.

10 min video

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customer project Energy

Real-Time Data & Custom Drivers Allow Power Supplier to Anticipate Demand

First Gen is one of the oldest and largest conglomerates in the Philippines that has an interest in power generation and power distribution. While Energy Development Corporation is a diversified renewable energy company, both are under the First Philippine Holdings Corporation – A Lopez Group of Companies, who constantly strive to meet the needs of its customers. In June 2021, the Enhanced Wholesale Electricity Spot Market Design Operations (EWDO) was launched. This officially started the new regulations for shortening of the dispatch interval: instead of a per-hour basis, it was transitioned to a five-minute interval. First Gen and Energy Development Corporation (EDC) have adapted the five-minute interval in their Central Dispatch Operations (CDO). This new regulation was addressed by installing multiple Ignition gateways for faster data monitoring, collection, and secured control of power generation across more than 30+ power plants (and counting). Controtek developed customized drivers to get the real-time dispatch setpoints from the Independent Electricity Market Operator of the Philippines (IEMOP) to meet the demands of the operations and compliance with the new regulation of the EWDO.

12 min video

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customer project Chemicals

Digital Troubleshooting Guide Boosts Chemical Company's Efficiency

Cooley Group has a corporate Manufacturing 4.0/Digital Transformation initiative that it is implementing using the Ignition platform. RoviSys was brought on to help guide Cooley Group on this journey and develop the functionalities it needed in a templatized way that promotes scalability and supportability. Cooley Group requested the use of Ignition to develop a Digital Troubleshooting Guide that operators could use to help resolve downtime events impacting their OEE. For this project, RoviSys implemented a creative solution that gave Cooley Group exactly what it asked for, yet made it easy for it to build and configure on its own within the Ignition designer.

3 min video

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customer project Water/Wastewater

Water Utility Seamlessly Transitions Operating Systems And Speed Development

Design and develop a new treatment plant HMI to replace WinCC and condense third-party applications into one platform.

9 min video

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customer project Oil and Gas

SCADA Screens Enable Unified Operations For Leading Energy Provider

PureWest Energy, the largest producer of natural gas in Wyoming, engaged a leading system integrator to develop SCADA screens for both the desktop and mobile platforms. The integrator created has created a development plan to build a customized, scalable SCADA system.

10 min video

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customer project Oil and Gas

Reliable Data Supports Cleaner Energy Initiative For 50 States

One of South Jersey Industries’ (SJI) key initiatives is to deliver on its commitment to provide cleaner energy. The generation of renewable natural gas facilities at dairy farms is a key production commitment for SJI. A modular production facility is required at each farm site, near the raw materials. The speed of deployment and number of sites involved demands the establishment of a universal architecture and platform for the integration of control and enterprise systems at the company. In addition, the distributed nature of the system and criticality to the energy infrastructure demand the highest level of security and reliability. Finally, SJI requires that all these sites be centrally monitored from an enterprise SCADA system that will also historize data for financial and regulatory reporting. The central importance of reliable data for continual operational financial justification proves the common Digital Transformation adage that “data is the new gas.” SJI Industries tasked Automated Control Concepts (ACC) to build a foundation for the application of key control and information technologies and systems that will allow the organization to realize world-class Digital Transformation and create a secure data pipeline. In doing so, SJI would be able to provide users at all levels of the organization with access to control system information. Through the strategic application of industrial information technologies, significant benefits are realized in the following areas: reliability, availability, visibility, and security. ACC successfully built and deployed this operational technology stack on Inductive Automation’s Ignition platform, which let ACC establish a scalable architecture to support plants/sites of varying sizes and complexity. The integration of data from the site’s control level, through various secure (DMZ) network layers to the corporate core network and cloud providers, has been addressed.

10 min video

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customer project Food and Beverage

Enterprise SCADA Gives New Zealand Meat Producer Standardized Control

Tamaki Control implemented a new Ignition Perspective standards framework for ANZCO Foods. This framework replaced unsupported SCADA systems and enabled new automation projects and ERP API integration solutions across its 10 manufacturing and processing sites in New Zealand. The project involved upgrading or installing Ignition 8.1 at each site and connecting them on the Gateway Network through an enterprise architecture with the Enterprise Administration Module. The result is a cohesive and efficient system that has positioned ANZCO Foods for continued success.

10 min video

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customer project Pharmaceuticals

New Control System Improves Safety And Compliance For Pharmaceutical Company

Initially, Zendal approached Optomation Systems to tackle their needs for monitoring unmanned storage units holding pharmaceutical final products for their customers. When Optomation introduced Ignition, it rapidly evolved into a larger project with a broader scope to encompass the data acquisition of varied equipment, process control and supervision, alarm notification, data historization, and automatic report generation. The main objective of the project was to implement a system that acts as a data repository for the information collected from the dedicated equipment in the different production areas and auxiliary services, both to satisfy regulatory requirements and prove compliance with CDMO obligations to customers. In addition, the system integrated new production areas into the system and expanded functionality to include control and supervision of several processes. Field devices and sensors are connected to controllers that execute automated sequences, and from Ignition, operators have full access to the operation, just like a traditional SCADA system.

10 min video

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customer project Oil and Gas

Numerous Custom Applications from One Platform for Provider of Gases, Materials, and Equipment

The customer suffered from a classic corporate administrative problem: too many of its critical processes were managed by a hodgepodge of spreadsheets and paper records. Off-the-shelf products solved some of these needs but were too inflexible to be adapted to the custom internal procedures. Ignition allowed custom applications to be built to satisfy these needs and gain wide community acceptance and shape corporate policy and culture.

8 min video

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customer project Mining

Cloud-Hosted Enterprise SCADA for Large Provider of Aggregate Material and Cement

Dolese Bros. is a large provider of aggregate material and cement throughout the state of Oklahoma. Over the past several years, Dolese has upgraded many of its quarries with advanced automation, networking, and operational systems. A key component of this strategy is the deployment of Inductive Automation’s Ignition platform at each quarry, and then a cloud-hosted enterprise-level Ignition system to provide reporting, visualization, and business system integration at a corporate level. Dolese enlisted the help of Industrial Networking Solutions (INS) to accomplish their goals.

5 min video

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customer project Pharmaceuticals

New SCADA Improves Productivity for Biomanufacturing Company

National Resilience Inc. offers a broad mix of customized manufacturing and development capabilities at their Mississauga, Ontario facility to serve the needs of biopharmaceutical companies at all stages of the drug development process – from pre-clinical development to commercial supply. Resilience requested Grantek’s assistance to develop an Ignition SCADA to support new GMP manufacturing processes in the building area known as the “H-Area.” This solution was needed to rapidly scale a brownfield contract pharmaceutical manufacturing facility, allowing Resilience to maximize their productivity and meet their commercialization goals.

6 min video

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customer project Manufacturing

Improved Monitoring of Power Generators Nationwide

Brown Engineers developed a USA-branded solution specific to their needs for monitoring a nationwide fleet of generators for high-reliability customers.

8 min video

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customer project Manufacturing

Industry Leader Reduces Paper, Gets Faster Reporting and Better Productivity

This project was created by FG Automação Industrial for Saint-Gobain, a world leader in the design, manufacturing, and distribution of materials and services for the construction and industrial markets. To better attend to their customers' needs, FG Automação Industrial used Ignition Perspective and Sepasoft's OEE Downtime modules. By combining these modules, they were able to transform the Saint-Gobain tube production management process into a robust, user-friendly, dynamic, reliable, and 100% digital interface.

7 min video

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customer project Transportation

New Mobile Capabilities for United Airlines at Houston Airport

In addition to the HMI baggage handling system Vision application running on the workstations for Houston Terminal C/E (and now B), the intent was to offer the same functionality on a mobile device, such as a tablet. While incorporating the same security roles as the Vision application, the operator on the tablet can view/acknowledge/shelve alarms, view graphics, view and interact with device statuses and controls, view statistics and view connection status details from the new Perspective application.

9 min video

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customer project Pharmaceuticals

Variety of Connections and Unlimited Licensing Aid Cancer Therapy

This project involved using Ignition in the personalized medicine industry to handle multiple communication protocols in one 21 CFR Part 11-compliant environment. The same regulatory data integrity requirements exist in personalized medicine as in large-scale productions and Ignition has proven to be a valuable tool because of its flexibility, mobility, and above all — device integration.

5 min video

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customer project Manufacturing

Improvements Beyond Expectations for Global Leader in Beauty & Wellness

This project was developed for a greenfield site, built for the manufacturing of beauty and wellness products. The customer had outgrown their original site and had to expand their production to meet demand. The new site had to provide a solution with improved visibility on their systems, services, and manufacturing processes, and provide consistency in the quality of their manufacturing procedures.

7 min video

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customer project Food and Beverage

Improved SCADA, HMI, and MES for Ninth-Largest Craft Brewer in United States

Stone Brewing is the ninth-largest craft brewing company in the US, located in Escondido, CA, and was founded by Greg Koch in 1996. The goal of the project was to upgrade the existing Siemens BRAUMAT brewing automation system with a new design consisting of Rockwell PLCs, networks, Ignition HMI, historian, batch, and MES software for the two brewhouses at Stone Brewing Company in Escondido, California.

6 min video

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Lower Costs, More Data for Australian Water Agency with Over 300 Sites Colette Matthews Wed, 10/19/2022 - 10:11

Project Scope:

  • Tags: 70,000
  • Screens: 880 screens and 450 popups
  • Clients: 1 fixed dedicated client (workstation), 5 web clients, with 20-25 mobile/tablet clients
  • Alarms: 4,500
  • Devices used: 80+ Red Lion Protocol Converters (DA30D); 75+ Teltonika RUTX09 4G Modems; PLCs - 80+ Koyo Click Plus, 60+ MELSEC across several varieties: MELSEC FX1N/60MRES, MELSEC FX1S/30MRES, MELSEC FX3G/40MRES, MELSEC FX3G/40MRES; 10 Modicon PC-E984-285
  • Architectures used: Ignition Standard architecture with redundancy
  • Databases used: 2 SQL Databases (System Data and History)
  • Historical data logged: 65,000 historized tags


Project Summary:

A regional municipal council has implemented the next generation of remote telemetry monitoring and data-driven decision-making. This represents a significant step for the water industry in Australia and provides access to the same data-driven decision-making process used by large water authorities for a fraction of the cost. Since implementing the new system, the council has seen the commencement of significant cost reductions, improved planning, and data-driven decision-making.


Problem:

Australia has a long history of remote telemetry operations with many water authorities covering huge geographical regions. Often these systems are based on old poorly secured technology (by current standards). This project is a great example of a small council in a growing region using a forward-thinking approach during their control system upgrade. 

Alexandrina Council is one of the fastest-growing regions of South Australia, with a population greater than 27,800. During summer, the population swells with visitors, requiring the council to account for this additional peak demand. The region is home to the Murray Mouth, Coorong, and significant environmental sites including Ramsar wetlands. 

The council had more than 300 remote sites across at least six independent SCADA technologies with very limited to no remote accessibility. This created a difficult asset environment to manage and meant maintenance teams were constantly traveling to collect data and spot-check the status of the different systems. 

The council’s wastewater team had a future vision to leverage the rich data capture and drive analytical tools to enable predictive maintenance for their sites. 

SAGE implemented a superior solution using Ignition Perspective, MQTT Sparkplug B, and LTE, that enables the council to:

  • Implement a large wide-area remote telemetry system with data buffering for a fraction of the price of other comparative solutions on the market.
  • Combine multiple SCADA and HMI technologies into a unified Ignition platform.
  • Use a mobile-first design approach that allows data to be accessed anywhere on any device, all developed/tested and commissioned once.
  • Store data from more than 300 sites and provide access to decision-making support tools.
  • Reduce maintenance costs via site visibility, reducing the amount of travel needed.


Solution:

The latest features of Ignition Perspective’s visualization platform were used to provide a flexible project. Taking a mobile-first approach allowed templates to be used across different devices (mobile, tablet, and desktop) without duplicating development effort. This was completed without negatively impacting the desktop environment, which includes full P&ID views using the latest Ignition piping tools.

The project is built around Ignition’s tight integration with MQTT Sparkplug B. It uses Red Lion DA30D units at each site as a common edge device which can communicate to the wide range of PLCs that the council has installed over 15 years. The ease of integration and data backfilling combine for a powerful solution at a fraction of the price of a traditional RTU architecture.

SAGE leveraged the web service connectivity, powerful scripting, and templates within Ignition to replicate an entire IoT system quickly. The Flovac IoT system is used as a data source, and Ignition’s graphics and data are all generated dynamically. This allows Ignition to be a single source of truth from an operator’s perspective and removes the need to manually update Ignition as new sites are added or removed in the IoT system. This significantly reduces the level of system maintenance required in the future.


Results:

The council gained full remote visibility of sites, with multiple external systems integrated into a single centralized SCADA. As a result, operators can access historical data, as well as intelligence (such as event markers) to improve troubleshooting and response times, from whatever location they need. 

SAGE takes a highly collaborative approach when working with software and hardware vendors. The requested features and improvements developed in this process change the industry for the better. Specifically, SAGE worked with the Red Lion team to improve how the MQTT backfilling process works and increase stability. Within Ignition, they were one of the first teams to implement the piping tool in a live system and provided valuable feedback on it and other critical features of Perspective like trending, alarm display, and shelving. 

Introducing new operations personnel to a SCADA system is time-intensive, so 3-5-minute training videos are embedded into the system. These recordings step users through common scenarios typically covered by in-person training sessions, such as simple navigation and color standards, through to complex features like trending. This also allows experienced users to re-familiarize themselves with infrequently used features. Fundamentally, this system supports and provides critical user tools for the operators, ensuring they remain at the center of application development.

The council’s on-call support has vastly improved - previously, any alarm would require travel to the site. Using Ignition’s alarm notification system, alarms are categorized and directed to the appropriate operations group, who can log in through their mobile device or tablet, and address the alarm with the operational intelligence they need. 

Operations now more effectively plan and schedule multi-site works by remotely monitoring site status to ensure a suitable operational state when they arrive at the next site to take samples and measurements.

Prioritizing alarms, reducing travel time, and performance-based maintenance create direct cost savings for the council, allowing funds to be redirected towards expansion plans. It also provides the council with the core infrastructure for analytics and machine learning tools to increase those savings even further.


Transcription:

00:18
Scott: I'm Scott Avis, senior systems engineer, and have been with SAGE Group for 12 years, delivering SCADA and telemetry solutions across a number of industries. SAGE Group is an Australian-based company with more than 600 people across two continents. We are a Premier-Level Integrator with Ignition. We have a presence in every state and territory in Australia and are focused on delivering a smarter future, better world. Alexandrina Council has a population of more than 27,800 residents across more than 1,800 square kilometers and is one of the fastest growing regions of South Australia. The region is a popular tourist destination with more than 800,000 overnight visitors each year. The Council originally had more than 300 remote sites across at least six independent SCADA technologies, with very limited to no remote accessibility. This created an asset environment that was difficult to manage and meant that maintenance teams were constantly traveling in order to collect data and spot-check the status of the district systems.

01:20
Scott: In 2021, SAGE Group began working with the Council to introduce an overarching control system across all their wastewater assets. This project involved Alexandrina Council's implementation of the next generation of remote telemetry monitoring and decision-making in wastewater. This represents a significant step change for the water industry in Australia and provides access to the same data driven decision making processes used by large water authorities for a fraction of the cost. Since implementing the new system, the Council has seen significant cost reductions, improved planning, and better decision-making. So before we take a look at some actual graphics, I'd like to discuss the design philosophy of this project. Initial discussions with the Council revealed their preferences for a highly mobile workforce. With this in mind, SAGE designed faceplates for mobile resolution first. These face plates are common between both the mobile and desktop environments. Everywhere possible, we focus development on faceplate templates, which are dynamically placed on the view interface, regardless of resolution.

02:24
Scott: So we'll start here with the map overview page. This page shows all the sites in the Council district. The pump station overview page provides a high-level status of all pump stations in a township, including pump status and sublevel. From the individual pump station page, Operations receive a more detailed view of site status, including pump operation, sump levels, pump statistics, site control. Both the pump station overview in this detail page are created dynamically based on site information in the system tag database and SQL tables. This is allowed for quick and simple site instancing. SAGE have utilized the new Perspective piping tool to create the P&ID pages operators are familiar with. One of the Council's existing more featureful SCADA installations was deployed across a vacuum pumping system. SAGE system engineers worked with the FLOW-VAC developers to utilize a new rest API service, which enabled replication of the FLOW-VAC SCADA system within the Perspective environment. This has enabled Ignition to fulfill the Council's desire for a single source of monitoring.

03:40
Scott: This implementation will even recognize when a new device is added on the FLOW-VAC side and automatically added to Perspective without any user interaction. In terms of actual graphics, you'll see, we have a graphical map showing asset locations, which can be filtered based on which pump station the vacuum site feeds, which gateway they communicate through. We have also developed a table view showing all sites. This table can be filtered based on any column value. Table rows can be selected to display additional site information, including a trend and statistics, which automatically update based on the trend time period. SAGE has developed a trend saving feature which allows operators to build their own specific trending. These trends can be saved and retrieved at a later date by themselves or another operator based on user credentials and page settings. Operator training is a small part of a project handover, but for new operators and those unable to attend training sessions can often result in a "here's the manual, have a read" approach. To mitigate this issue, we've embedded training videos directly into the SCADA application.

04:50
Scott: This allows any operator to access short and specific training videos on demand. In addition to the new operator training, we also foresee an experienced operator accessing specific videos for SCADA elements they don't often use, such as advanced trending features like multi-plot trends. One of our team members had a stroke of inspiration and developed a dark mode feature. Now every graphic in the system functions in both a light and dark mode. You can see this as I cycle through the graphics. Everything I've mentioned previously works on mobile and tablet environments. Displays automatically scale up and down based on device resolution. This results in a SCADA system which works as well on a mobile device as it does in a multi-monitor operator control room. At its core, Council operations has been significantly improved. They have the data to drive informed decision-making and the ability to push that data into other analytical platforms. They have SCADA access from any location on any device and minimized incident response time through prioritizing of alarm events.

06:03
Scott: This has resulted in a significant reduction in transport costs and operator driving time. SAGE has delivered all this at a fraction of the cost of a traditional RTU wide area communication network, saving the Council money, allowing prioritized spending and benefiting Council residents as their funds can be redirected. Looking forward, the Alexandrina Council is discussing growing the SCADA system by incorporating additional storm water and irrigation sites.

    End User Description
    Alexandrina Council is uniquely positioned in the picturesque Southern Fleurieu Peninsula of South Australia, approximately 80km from Adelaide CBD. Alexandrina Council comprises some 182,684 hectares and is one of the fastest-growing regional areas in South Australia – experiencing peri-urban trends while also noted for its high-quality agricultural production (the second largest industry in the region). The Alexandrina vision is about ‘connecting communities’ through regional innovation, a thriving environment, quality of life and wellbeing for all, increasing cultural vitality and activating vibrant spaces.<p>
    <strong>Website:</strong> <a href="https://www.alexandrina.sa.gov.au/" target="_blank"> alexandrina.sa.gov.au</a>
    Industry
    Integrator Description
    SAGE Group is a global company with a team of more than 600 people spread across two continents. As an integrated industrial digitalisation services provider, SAGE combines the perfect balance of technology, process, and capability. SAGE Group includes specialist offerings – SAGE Automation, Nukon, Embedded Expertise and Skills Lab – that together deliver seamless support and provide the keys to successfully accelerating our clients on their digital journey. Our purpose is to partner with clients across defense, energy, manufacturing, resources, utilities and transport to create a smarter future, better world.<p>
    <strong>Website:</strong> <a href="https://www.gotosage.com/" target="_blank"> gotosage.com</a>
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    Lower Costs, More Data for Australian Water Agency with Over 300 Sites
    Video Duration
    408
    Wistia ID
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    Lower Costs, More Data for Australian Water Agency with Over 300 Sites
    Integrator Company Name
    SAGE Group
    End User Company Name
    Alexandrina Council
    customer project Manufacturing

    Global Automotive Machinery Company Gets Single Source of Truth in Every Department

    Ignition is used to create a SCADA/MES application that replaces a lot of separate Excel sheets and an old Citect SCADA platform. By using Ignition, AT-Automation instead created a single source of truth for every department (production, process engineering, technical service, quality, logistics) within the company.

    7 min video

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    customer project Oil and Gas

    Modern HMI/SCADA Improves Oil Pipeline for Global Agribusiness Cooperative

    Streamline Control worked with CHS Pipelines and Terminals – a leading global agribusiness owned by farmers, ranchers, and cooperatives across the US – to replace a legacy SCADA with a new system built around open standards for communication (MQTT/SPVB) and utilizing Ignition at all levels of the Purdue Model. Streamline was tasked and successfully executed all project activities including designing the SCADA architecture, developing high-performance HMI displays in Vision, developing a robust and comprehensive tagging/asset structure for each asset location, building Perspective displays for enterprise users, integrating Ignition with leak detection systems, developing applications in Ignition used for batch tracking, pig tracking and compliance.

    7 min video

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    customer project Energy

    Enterprise SCADA Streamlines Processes for Renewable Energy

    SB Energy engaged Vertech to provide a world-class enterprise SCADA solution for their new remote operations center. They needed a single-platform SCADA system to oversee six solar locations across North America and report industry-standard KPIs and data analytics in real-time.

    9 min video

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    New SCADA and Greater Mobility for Large Water-Management Agency Colette Matthews Wed, 10/19/2022 - 09:43

    Project Scope:

    • Tags: 50,000
    • Screens: 1,000
    • Clients: 50 users
    • Alarms: 20,000
    • Devices used: 575
    • Architectures used: Standard with VMWARE Esxi
    • Databases used: PostgreSQL
    • Historical data logged: 40,000

     

    Project Summary:

    The evolution of Réseau31 agents' missions requires more and more mobility and access to management and supervision tools using mobile terminals (smartphones, tablets). In addition, the rapid changes in the infrastructure to be monitored and operated (organic changes in the network, maintenance, new contracts, etc.) require frequent changes to the applications.

     

    Problem:

    The legacy supervision application does not have mobility functionality nor the possibility to create/modify projects online; incidentally, internal and external collaborative work (such as working with subcontractors) is impossible.

     

    Solution:

    Réseau31 — a public union for water, sanitation, and irrigation services in Haute-Garonne, France — selected Ignition by Inductive Automation as the new software platform to renovate its control system. The mission was executed with several companies collaborating at different levels: general design assistance, project development and deployment.

    Réseau31 has a large diversity among its 1,400 facilities, including water treatment plants, mountain catchments (basins), dams, and hydroelectric plants. Ignition, with its Perspective web visualization module, has made it possible to meet the need for ubiquity; any agent or client, depending on its credentials, can use the application on a desktop computer, in the machine room on a panel PC, and on a tablet or smartphone. Similarly, the application was developed to be an object-oriented language, meaning that changes could be made once, then deployed to all clients. 

    The Ignition platform has also made it possible to create not one application (replacing the legacy one), but several, using a multi-project approach. On the same server. For a single license fee. To date, Réseau31 has a supervision application and a hypervision, a decision support tool dedicated to managers and department heads.

    The needs covered are broader: control and command, monitoring of the overall operation of the water network (volumes distributed, flows, leak detection, etc.), monitoring of water quality, and monitoring of general consumption. Useful indicators such as m3/kW are now possible and will allow better management.

      End User Description
      Réseau31 supports local development, perpetuates and develops local actions in the fields of water management by relying on reinforced means of expertise and operation. Réseau31 has 243 members: 228 districts, 14 groups of districts and the Departmental Council of Haute-Garonne. This operation allows it to take into account local realities, starting from the needs expressed by the elected officials in the service of the citizens. Réseau31 is a mixed syndicate which includes: The department of Haute-Garonne, 250 local authorities of Haute-Garonne, and 30 inter-municipalities (syndicates, communities of communes, and communities of agglomerations).<p>
      <strong>Website:</strong> <a href="https://www.reseau31.fr/" target="_blank"> reseau31.fr</a>
      Industry
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      New SCADA and Greater Mobility for Large Water-Management Agency
      Video Duration
      446
      Wistia ID
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      End User Company Name
      Réseau31
      customer project Food and Beverage

      Data from Numerous Processes Aids Large Salmon Producer

      This project has been developed by employees at the automation department of Nordlaks Produkter AS for the Nordlaks group. The project consists of several departments where operators can control entire processes and managers can extract information and data all the way down to the component level.

      8 min video

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      Largest Publicly Traded U.S. Water/Wastewater Company Benefits from Enterprise Solution Colette Matthews Tue, 10/18/2022 - 14:17

      Project Scope:

      • Tags: 50,000+ and growing
      • Screens: 100s and growing at the SCADA level
      • Clients: (5) load-balanced front-end servers to serve up 100s of Perspective sessions simultaneously at the enterprise level
      • Alarms: 10,000+ and growing at the SCADA level
      • Devices used: 100s of PLCs of many different types
      • Architectures used: Hub and Spoke/Scale Out Architecture
      • Databases used: (2) Microsoft SQL Server at the enterprise and growing at the SCADA level
      • Historical data logged: Millions of data points, and growing


      Project Summary:

      More organizations are bringing Information Technology (IT) and Operations Technology (OT) together to assist in business decisions at every level of the organization. American Water teamed up with Flexware Innovation and Automated Controls Concepts (ACC) to create an Ignition ecosystem for SCADA/HMI standards, central data collection and analysis, and integration with other backend systems to support data-driven decision-making across the company. This project was the first and largest-scale standardization of their operational technology systems, and consisted of converting an outdated SCADA system to a modern system that is ISA 101-compliant. Ignition Perspective and Cirrus Link MQTT modules were included as key parts of this solution.


      Problem:

      The first area that American Water wanted to improve was the lack of SCADA/HMI standards at each of their sites. American Water has hundreds of water and wastewater locations across the United States. These systems were on different platforms and utilized different types of colors and symbols to control the processes. The company needed a way to normalize safe and typical operating conditions so that when an abnormal event occurs, the operator has the pertinent information to help make the correct decisions. However, with different standards deployed at these plants, the end user would need to be familiar with all the different symbols and styles across the enterprise to be effective in each of these systems.

      Another goal was creating a single portal to view key performance indicators from all of the plants. To attain Digital Transformation across the organization, there must be a standard way to get the data from the systems to a central location at the enterprise level. American Water had multiple different systems that contained data for its site or region, but there was no way to view that data without direct access. Even then, comparing data across systems became a difficult task. There was no central location to aggregate all the information needed for data-driven business decisions.

      Finally, American Water faced the challenge of bringing in data from external systems such as an asset management system and Geographic Information System (GIS). American Water needed a platform that could not only pull operational data up to a central location but also bridge the gap to other organizational information systems. This would allow American Water to further take advantage of the operational data by providing more definition and context than it could provide on its own.


      Solution:

      To solve each of these unique challenges, Flexware and ACC worked together to leverage their existing expertise with the Ignition platform and the water & wastewater industry to create a system that is robust and flexible for the whole enterprise.

      Perspective was used to create a SCADA/HMI platform standard across all American Water sites. The standard was built around the ISA 101 High-Performance HMI practices to highlight abnormalities in the system and increase operator awareness. Styling, color standards, and theme guides were created to promote a common look and feel across processes, sites, and systems. This allows operators to easily understand new systems. In addition, a library of process objects was created to accelerate legacy systems as a jumpstart to their Ignition conversion and development process.

      To create a central place to view the data, an enterprise portal was built. The enterprise portal organizes the data being pulled from the local systems and displays it in an intuitive way that is easily consumed by end users from multiple disciplines. This portal serves as the single place to aggregate and analyze the data. Tools have been developed to allow deeper analysis at any level of the business. The end user can compare cost savings and efficiencies across the sites to help drive informed decisions.

      American Water also utilized Ignition’s vast integration capabilities to interface with other systems. Ignition is securely moving operational data from the SCADA implementations at the sites to the portal using Cirrus Link’s MQTT modules. Data is also being integrated from existing OSI PI servers using Ignition’s OPC COM DA Module to communicate directly with that infrastructure. Finally, Ignition is using REST API calls to communicate with American Water’s internal GIS system for asset information.


      Result:

      With limited training, the American Water staff resolved each of the problems mentioned above. Several SCADA conversions to Ignition have been executed, or are in flight, using the SCADA/HMI platform and standards developed. Data from new and existing deployments is being sent up to the enterprise portal and organized for consumption. Additionally, the integrations with the other systems have been put into place to give the operational data even more context and drive deeper analysis. American Water now has more efficient decision-making capabilities, and their process for adapting and making changes is seamless. The ability to run Ignition on anything that has a web browser helps save time, and provides them with adaptability and a lower cost to access SCADA.

      This project is a work in progress. What has been achieved thus far will lay the groundwork for future integrations. As sites are converted and more data is available, the power of this system will continue to grow. Continued functionality is under development to create predictive analysis for when assets are being depleted, in-depth alarming at each level of the infrastructure, cost analysis for processes across systems, and more.


      Transcription:

      00:16
      Reese: I am Reese Tyson, I'm a Team Lead here at Flexware Innovation. So here at Flexware Innovation, we are a systems integrator and we focus on projects all the way down from the shop floor all the way up to the top floor. We range in many different verticals across the manufacturing space. The solution that we have built for American Water is really an Ignition ecosystem that is comprised of three different parts. The first being an HMI/SCADA standards platform, the second being a central place to view all of the data across American Water, and the third being a integration layer with Ignition that allows us to pull in data from other systems and provide more context.

      00:57
      Ryan: I'm Ryan Love. I'm the Superintendent of Operations for Indiana American Water. American Water is the largest publicly traded water and wastewater utility in the United States. Indiana American Water is a regulated water and wastewater utility with approximately 320,000 customers and is a subsidiary of American Water. Our previous system was becoming hard to maintain and find support for. Moving to Ignition has opened up a world of possibilities from maintenance, support, and expansion. My background is in automation and controls. So knowing where we came from and where we are today with Ignition has made a world of difference. That said, we are about six months into this conversion project, and we are just scratching the surface on its capabilities.

      01:38
      Reese: The American Water project team consists of three main parts. The first being the American Water personnel, they provide a great IT infrastructure background. The second being Automated Control Concepts which is another systems integrator that we partnered with and they provide a great amount of understanding of the water/wastewater space. And the third being us here at Flexware with our vast Ignition experience on many different projects we've executed. The key parts of the solution really starts with the Ignition platform and its vast amount of devices and drivers that it has built into the platform. And then on top of that, we are able to utilize the Perspective Module which allows us to view screens on many different devices as well as the MQTT modules which allow us to bring up that data from the sites into that central enterprise.

      02:32
      Reese: MQTT is a really big part of this project because of three main points. The first one being, it's very lightweight and we can load it onto many different devices out in the field. Second being, it's very scalable. And the third is, well, Ignition has built-in MQTT modules that we are able to use, and so we're able just to take advantage of this right out of the box.

      02:53
      T.J.: I'm T.J. Holt, I was a SCADA Architect at Flexware Innovation for this project. The special challenges were converting from an outdated SCADA system to a more modern SCADA system that is ISA101 compliant. With Ignition's versatile components, we're able to create a process object library and a dynamic navigation structure using Ignition integration. The biggest strength of using Ignition is the ability to templatize the objects and to utilize the inheritance to keep those components and objects in a central location. The new screens allow the operators to see the key metrics for each of the processes within the area. In addition to using the ISA101 standard, they're able to efficiently react to critical alarms within each of the processes. The best feedback we've gotten from the operators is Ignition's ad hoc trending capabilities, the ability to save trends per user, and just the quickness of the system overall.

      03:52
      Rob: I'm Rob Raffaele, Senior Director of Enterprise Architecture and Operational Technology here at American Water. The Ignition project is important to American Water because this is the first and largest scale standardization of our operational technology systems. We plan to deliver consistency across all of our water and wastewater plants in a consolidated view for operations and IT alike. The new system results in more efficient decision-making and more access to data for people in operations, water quality, and engineering. We are fully in on the technologies that Ignition delivers, both Perspective and MQTT. We love the mobilization aspects of Perspective and the lightweight data transfer nature of MQTT.

      04:39
      Ryan: Switching to Ignition has impacted us in many ways. One of those is the ability to run Ignition on anything that has a web browser, this provides a lower cost to access through SCADA as well as adaptability into the future. Switching to Ignition is also saving time. Being called with an emergency situation in the middle of the night used to take upwards of 10 minutes to be able to remote in via laptop. Now, I can just pull my phone out and open up the web browser and be able to see the same data the operators see.

      05:08
      Rob: Ignition absolutely helps information and operational technologies work together with common platforms, common systems, and common tools. Now both sides of the house speak the same language. It's extremely valuable to have more access to operational data as now teams can self-serve where in the past, it was a very manual operation to get that into their hands.

      05:33
      Reese: So Ignition's flexibility allows us to do many different things. It allows us to scale out really well with the ability to add different types of servers, whether it's a front-end server, whether it's a back-end server, or whether it's a SCADA server that has both of those included. The scalability and the flexibility of that platform just allows us to do so many different things. So this is the American Water enterprise portal that we have created to view all of the data across American Water in one central location. On the left-hand side, you can see the American Water organization broken down into multiple states. If we drill in through the data model all the way down to the specific water treatment plant, we can drill all the way into every single piece of data that we wanna see on these different KPIs and these widgets. You'll notice it's being rendered as sparklines and bar charts as to what type of data that we wanted to see.

      06:27
      Reese: We can also view this information on a map as well. We can drill again through that data model all the way down to that water treatment plant that we were just looking at on the other screen and see where that information is and the system that it is inside of. 

      06:45
      Reese: Automated Control Concepts was a huge partner right from the get-go. They're able to bring invaluable information about the operational data and the day-to-day processes that the operators would go through. In addition, they're very heavily involved with data mapping and making sure the data that we're bringing up to the enterprise portal is valid and accurate.

      07:06
      Rob: This project has been going on for the better part of a year. And we would be remiss if we didn't mention our partners, Automated Control Concepts, ACC, and Flexware Innovation. Both of them have been key to helping us deliver the Ignition platform and continue to be key integrators and partners for our future of standardization.

      07:27
      Ryan: Ignition has been extremely easy to use. Being able to adapt and make changes is a seamless process now.

      07:33
      Reese: Ignition's unlimited license was a huge factor when deciding which platform to go with. American Water's ecosystem comprises hundreds of sites across the US and so as we scale out that cost-benefit really, it becomes a huge deal in the end.

      07:50
      T.J.: In the future, we would like to expand upon the tools that we've created. We currently have tools that can modify the SQL model and auto-generate tags. In the future, we're hoping to create a tool to auto-generate the view structure.

      08:06
      Rob: We fully expect Ignition to help with other opportunities in the future, both integrating some of our meter data and data into our data lake.

      End User Description
      American Water is the largest and most geographically diverse publicly traded U.S. water and wastewater utility company. American Water employs more than 6,400 dedicated professionals who provide regulated and market-based drinking water, wastewater and other related services to an estimated 14 million people in 24 states. American Water serves residential homes and businesses through its regulated subsidiaries, as well as perform contract operations for military bases and municipalities that own their utility systems. The company develops and implements solutions to meet the country’s many water challenges.<p>
      <strong>Website:</strong> <a href="https://www.amwater.com/" target="_blank">amwater.com</a>
      Industry
      Integrator Description
      Flexware Innovation is the go-to engineering firm for forward-thinking manufacturers that need to integrate their business and production systems to maximize their resources. Founded in 1996, our highly-skilled teams of dedicated professionals work side-by-side with customers to leverage technology to solve real business problems by providing best-in-class software development, automation engineering, manufacturing systems integration (MES, HMI/SCADA, & ERP), business intelligence solutions, Internet of Things (IoT) devices, and specialized product development.<p>
      <strong>Website:</strong> <a href="https://www.flexwareinnovation.com/" target="_blank">flexwareinnovation.com</a>
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      Largest Publicly Traded U.S. Water/Wastewater Company Benefits from Enterprise Solution
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      Largest Publicly Traded U.S. Water/Wastewater Company Benefits from Enterprise Solution
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      customer project Oil and Gas

      Edge and MQTT Help Convert Toxic Gas to Sulfur

      Streamline Innovations operates natural gas treating units in South and West Texas that convert hydrogen sulfide (H2S) into fertilizer-grade sulfur. Hydrogen sulfide is an extremely toxic, explosive chemical found in most natural gas.

      8 min video

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      customer project Water/Wastewater

      More Data for State’s First Membrane Bioreactor Wastewater Treatment Plant

      This was a SCADA project for the first membrane bioreactor wastewater treatment plant in the state of Arkansas. The City of Decatur’s plant treats water from municipal, industrial, and commercial sources. The new SCADA system provides the Utilities Department with real-time decision-making data it had never had before.

      6 min video

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      customer project Oil and Gas

      Cloud, Edge and More Enable a Fast Solution for Numerous Sites

      ARB Midstream acquired a new pipeline asset which includes 36 RTUs and central gathering locations. As part of the agreement, ARB was required to completely take over pipeline SCADA in four months. Challenged with this aggressive schedule, ARB contracted Industrial Networking Solutions (INS) to deliver a SCADA solution offering cloud-based reporting, management, visibility, control, and a communications network with failover capabilities and store-and-forward technologies.

      7 min video

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      customer project

      New Mobile Capabilities Bring More Data to Decision-Makers

      San Bernardino County in Southern California was looking for its next-generation visualization and control system for its landfills. Piloting the San Timoteo Landfill allowed SCS Remote Monitoring and Control (SCS RMC) and Corso Systems to provide major upgrades, use a flexible, scalable platform including Ignition 8 and Ignition Perspective, and integrate next-generation options such as 3D imaging from drones and virtual reality (VR).

      7 min video

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      customer project Energy

      More Than 30 Solar Sites on One Platform

      This project for Ecoplexus was the creation of a standardized, customizable system designed to handle the needs of large-scale solar and energy projects that are capable of deep data acquisition and manipulation, and most importantly, control. This new system for Ecoplexus culminated in the creation of NextDAS, a ground-breaking operations and management platform that is completely Ignition-based.

      6 min video

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      customer project Food and Beverage

      Improving Product Quality and Quantity

      The project applies a SCADA system for controlling, visualizing, and data acquisition for an automatic batch system, joining the three areas of the process: nutrition, production, and operation. The objectives of the project were to reduce production time, production cost, and waste of raw material — improving the product quality and quantity.

      5 min video

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      customer project Pharmaceuticals

      Meeting 21 CFR 11 Standards for Pharma

      Bachem Americas, a pharmaceutical company, designed and built a new cleavage unit for its chemical process at its Vista, Calif. facility. Inductive Automation’s Ignition software was used as a uniform HMI for the cleavage unit control system to provide fast and reliable access for monitoring data and sending commands securely.

      6 min video

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      customer project Aerospace

      Fueling Planes at America’s Eighth-Largest Airport

      The Ignition project controls the entire fuel farm at the airport. The project was designed to acquire highly accurate SCADA information from the fuel farm and provide an HMI that is operator friendly. This allows the operator to easily identify and correct any issues that arise on the fuel storage and delivery system.

      8 min video

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      customer project Water/Wastewater

      Improving Efficiency in Filter Process for Water Utility

      To increase flow rates at its water treatment plant to meet rising demand, the City of Hot Springs needed to upgrade its antiquated filter controls as well as the filters themselves. Brown Engineers helped the City use its recently installed Ignition SCADA platform to dramatically improve the automatic backwash process, conserve water, improve water quality, and initiate collection of filter data needed to extend regulatory run-time limits.

      7 min video

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      customer project Water/Wastewater

      Water Agency Gets Unified Platform, Better Reporting, and More

      H2O Innovation turned BRPUA’s antiquated, incohesive SCADA system into a new state-of-the-art Ignition redundant SCADA system. A key part of the project gave BRPUA a much faster, easier way to submit reports to the Texas Commission on Environmental Quality (TCEQ). Other reports were automated as well.

      6 min video

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      customer project Water/Wastewater

      Two Water Agencies Modernize and Expand Their SCADA Systems

      This is a modernization project, as two water agencies moved from old systems to new ones. The two neighboring water agencies have been so pleased with initial results, they are expanding on Ignition to include more of their operations.

      6 min video

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      customer project Food and Beverage

      Collaboration Brings Unified Platform for New Food-Production Plant

      JTM Food Group challenged ECS Solutions and Blentech to create a SCADA system that included the full spectrum of process automation for its new state-of-the-art production facility.

      6 min video

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      customer project Food and Beverage

      World's Largest Yogurt Plant Streamlines Clean-In-Place

      Operators in Chobani’s KDB control room are tasked with scheduling 150 possible washes on the 18 available lines of the centralized CIP system. They must prioritize certain washes for critical lines, schedule time for wash validations, and quickly deal with changing schedules and other interruptions. Chobani operations approached its automation department and asked for a software scheduling solution. The automation department immediately suggested Ignition and talked to Tamaki about integrating the solution.

      7 min video

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      customer project Food and Beverage

      Industry 4.0 Closes the Gap Between Customer and Supplier

      This project connected Shopify’s e-commerce storefront ordering process directly to YourCoffee’s production floor. Using Ignition SCADA with web services APIs and Beckhoff PAC-based factory automation platform, ESM Australia delivered YourCoffee the Industry 4.0 tools to connect, evaluate, structure, and control information and physical processes — enabling it to achieve highly dynamic production goals, without limits.

      3 min video

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      customer project Automotive

      Improving Productivity for Dana Incorporated

      This project was developed to provide real-time statistical analysis and visualization of machine data to allow for better and faster decision-making concerning performance and efficiencies. The project also needed to be flexible enough to adapt to future needs of the client company, Dana Incorporated.

      5 min video

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      customer project Agriculture

      Animal Nutrition Producer Sees Benefits Throughout Facility

      The project uses Ignition Vision Modules to develop a custom Manufacturing Execution System (MES) solution. Ignition delivers information that enables the optimization of production activities from order launch to finished goods. Using current and accurate data, the system initiates, responds to, and reports on plant operations as they occur.

      7 min video

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      customer project Mining

      Analyzing Plant-Design Scenarios

      For this project, ANDRITZ Automation used Ignition to create an engineering tool that performs detailed analysis of the preliminary design of a plant. ANDRITZ creates an engineering design model of the plant in its proprietary simulation software called IDEAS. Then, Ignition controls the execution of a multitude of design scenarios and aggregates the results for the user, graphically presenting the impacts of design choices on parameters like plant throughput and energy consumption.

      8 min video

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      customer project Oil and Gas

      Improving Real-Time and Historical Knowledge with MQTT

      Magnetrol is a global level and flow solutions provider. The company wanted to leverage the native intelligence that was built into its Smart Level transmitter products but was left stranded in the field. The goal was to use IIoT technology to access information from Magnetrol devices in a cost-effective manner. Magnetrol wanted to get the data into an easily accessible infrastructure — to help transform its “reactive” service model to a “proactive” model.

      5 min video

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      customer project Oil and Gas

      Making Data Available Across Several Divisions

      Kinetrex contacted Miller-Eads Automation to request a proposed solution. After investigating the problems caused by the combination and limited functionality of the many software packages, Miller-Eads presented a proposal using Ignition to integrate the many types and versions of software and expand the overall system’s capabilities.

      7 min video

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      customer project Oil and Gas

      Greater Accuracy Monitoring Gas Usage in Bangladesh

      The HIT System is an Ignition-powered application designed to facilitate more accurate gas utilities monitoring in Bangladesh. It includes a CRM for managing customers as well as a data storage and analysis portion that runs against incoming gas usage statistics.

      6 min video

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      customer project Oil and Gas

      Complex SCADA Migration on a Huge Scale

      This project was done for Pioneer Natural Resources. It involved the migration of a legacy SCADA system to the Pioneer Enterprise Ignition SCADA System and integrating the asset with Pioneer Corporate Applications.

      7 min video

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      customer project Food and Beverage

      Ignition Aids Major Growth for Food-Industry Leader

      SugarCreek is a very large, dynamic, growing food manufacturer which requires plant-floor data to allow Operations to identify and solve problems across six manufacturing sites. Over the past few years, Ignition has enabled SugarCreek to collect and analyze new levels of data with significant results including cost savings and improved efficiency.

      7 min video

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      customer project Transportation

      SCADA and More for Eight Road Tunnels

      Bouygues Energies & Services is using Ignition in several capacities as part of its project for the L2 bypass in Marseilles. Bouygues created the Centralized Technical Management (CTM) system with Ignition and Siemens PLCs. The system keeps eight road tunnels under constant surveillance along their entire length of 6.2 miles. CTM processes data from over 12,000 I/O control points and more than 120,000 tags.

      8 min video

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      customer project Water/Wastewater

      Two Customers See Big Improvements, Can Share Data

      The Mountain Regional Water District (MRW) and the city of Park City both wanted to improve their HMI/SCADA systems. Each was seeking a more reliable and robust HMI that could provide good data visibility, alarming, and expandability at an affordable cost. Further on in the project, there became a greater need to share data between the two entities and run automated reports.

      7 min video

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      customer project Water/Wastewater

      System-wide SCADA Migration Brings Greater Capabilities and Lower Costs

      Brown Engineers replaced CAW’s obsolete, clunky and expensive SCADA system with a secure, future-proofed, Ignition-based system that has two master control points and allows full use of all operational data collected.

      9 min video

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      customer project Food and Beverage

      Improving Efficiencies at Two Facilities While Creating Standards for a Third

      This project by Automation Solutions Ecuador (ASE) applied a SCADA system for controlling and visualizing the batch dosing process, which is the first-step process for animal food production. The Batch Dosing System accomplishes this and also registers all raw material consumption at two production facilities. The Batch Dosing System also controls the inventory of raw material in the hoppers. It records the consumption of raw material by indicating the lot from which the raw material is coming.

      6 min video

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      customer project Manufacturing

      Custom Ignition Drivers for Plex and SAP Improve Inventory Accuracy

      This project features automated recording in an ERP system using custom Ignition drivers and screens for Plex and SAP.

      6 min video

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      customer project Manufacturing

      Less Paper and More Data for Better Decision-Making

      JLG Industries wanted to standardize on one software platform for the entire manufacturing plant — a platform that would unify existing applications and devices, eliminate paper forms, provide historical data storage, and provide MES capabilities.

      6 min video

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      customer project Aerospace

      Building a Data-Rich Manufacturing Operations Management System

      This project was a manufacturing operations management system created for aerospace research. The system was built using the standard Ignition product, without any third-party modules. The result was a data-rich, non-restrictive system.

      9 min video

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      customer project Energy

      Connecting Numerous Systems for a Brighter Solar Future

      This project involved working with Canadian Solar to create CSEye — a custom hybrid asset performance monitoring and computerized maintenance management system (CMMS) application for the solar photovoltaic (PV) operations & maintenance sector of the renewable power-generating market.

      7 min video

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      customer project Energy

      A Variety of Improvements for Solar Plant

      The need is to monitor in real-time the photovoltaic (PV) plant equipment to ensure high availability. This includes more than 1,700 trackers which need to be perfectly oriented. Another need is to control the performance of the PV plant.

      9 min video

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      customer project Automotive

      Beyond Customer Expectations for a Fraction of the Typical Cost

      This was a SCADA/HMI pilot project for automated statistical process control (SPC) with in-line data capture of incoming and outgoing quality of vehicle-door and hood-gap measurements using wireless digital calipers. The customer — a large automobile manufacturer — was seeking a solution that would help it improve the manual process of measuring door and hood gaps by team members on a moving assembly line.

      7 min video

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      customer project Data Center

      Greater Access to Info Across 22 Data Centers

      This project was a colocation data center HMI for electrical power distribution, thermal management and capacity planning. It provides navigation, equipment detail, history, trending, notifications and alarms.

      5 min video

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      customer project Manufacturing

      Visualizing Data for Improved Repeatability

      RollDVR provides deep-drill click visualization and analysis of roll manufacturing wind-in and wind-out properties. The project allows roll build replay with direct association of machine process points, recipe settings, and time series charting using a slider on a scaled vector graphic to select point-of-time for display. Through the use of a best-fit algorithm, roll-to-roll process point comparison is available to assist in root cause analysis.

      8 min video

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      customer project Energy

      SCADA Solar Energy System Improves on Industry Status Quo

      Vertech built a SCADA solar energy system with Ignition, providing cutting-edge, user-friendly monitoring and control of five utility-scale solar power plants.

      5 min video

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      customer project Manufacturing

      Ignition Helps Huge Company Empower Thousands of Users

      This project is for LafargeHolcim’s Technical Information System (TIS). The TIS software will become the primary place to access industrial performance information for the cement branch of the company. The aim is to have 30,000 employees using it. The goal is to have a very high level of user interface, with no training needed.

      7 min video

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      customer project Food and Beverage

      Large Plant Sees Numerous Improvements from Switch to Ignition

      The purpose of this project was to swap out the site’s previous SCADA system with Ignition. The site previously used 23 servers to run its SCADA system; the Ignition system now uses four. The site previously ran on Windows, but as a part of this upgrade the SCADA system (servers and clients) is exclusively running on Linux. This has provided a lot of flexibility to tailor the system architecture to the site’s needs.

      3 min video

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      customer project Military

      Detailed Simulation Greatly Improves Training

      There are a variety of limiting factors with traditional hands-on equipment training. Most pieces of equipment are not built for the constant repetition required in a classroom or hands-on training environment. In most cases, the number of students exceeds the available equipment — so training is often done in stages rather than in sequence. In addition, valuable and strategic training time is often restricted by the setup and tear-down time. Weather delays are a continual problem for in-the-field, hands-on training. The use of hazardous chemicals and disposal are of real concern as well as the filling and phasing on and off of various component systems such as hydraulics or tank fills. These are all issues that limit the actual training time.

      7 min video

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      customer project Energy

      Power Plants Get Data to Central Agency via Ignition

      The Control Center of Energy (CENACE) is responsible for coordinating the power system’s operations in terms of security, quality and economy. As a result, CENACE requires information from all plants of energy generation for coordination, monitoring and real-time control of the National Interconnected System. To fulfill the purpose of transmitting information to CENACE, the Electric SCADA Project For the Thermal Power Plant of Manta was developed.

      7 min video

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      customer project Energy

      New SCADA Provides Numerous Benefits While Keeping Legacy Hardware

      The client has an aging system, Siemens FactoryLink, that is at the verge of discontinuation, and they must be upgraded to one that is currently supported while also bringing upon improvements to rationalize the cost of the change. The challenge is to create a system that is able to tie together all the legacy devices with their wide range of configurations and transition to Ignition within a set of defined phases.

      6 min video

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      customer project Oil and Gas

      Real-Time Data Easily Shared for Oil Well Testing

      PROS, a Professional, Reliable Oilfield Service company, provides third-party oil well testing services. PROS needed a way to collect and store this data accurately and efficiently. Tyrion Integration provided a cloud-hosted web application to provide real-time remote monitoring and control of each unit. This was accomplished with the use of Tyrion’s Nucleus and a combination of Ignition Gateways. Nucleus is a new device created by Tyrion Integration that takes the place of a cellular modem, PLC, industrial PC, and HMI.

      7 min video

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      customer project Oil and Gas

      Ignition Makes Data from Multiple Sites Available in One Place

      Gente Oil’s SCADA system is a centrally managed system of the oil process from extraction to transportation. The SCADA allows users to visualize and interact with the different instrumentation and actuators involved in the process.

      5 min video

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      customer project Water/Wastewater

      Solving Several Problems for Water/Waste Water Plants

      In 2015 we built new pumping stations for waste water. At the same time the decision was made to upgrade the existing SCADA and PLC systems. The old SCADA system was installed in the late ‘90s and PLC systems were built with technology from the ‘80s with a serial communication interface. The requirement was that the new system would be able to handle even the old PLC systems and spread the investment costs for upgrading. At the same time, a fiber network covering the entire county was built.

      6 min video

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      customer project Water/Wastewater

      Water Authority Leverages Ignition for Faster Processes & Lower Costs

      The Arapahoe County Water and Wastewater Authority operates a Collection and Distribution (C/D) system of approximately 30 sites, consisting of waste water lift stations, water wells, storage tanks and booster pump stations serving approximately 3,500 homes and businesses in an eight-square mile area south of Denver, Colorado. The system uses over 30 Rockwell programmable controllers at each site communicating to three Master Terminal Units via serial radios which transmit data across Ethernet radio to a Master PLC, using over 300 message instructions.

      6 min video

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      customer project Food and Beverage

      Unique White Box Quickly Reveals Valuable Data

      Ignition is used in 11 of the top 50 craft breweries in the United States, yet most of the other breweries have not heard of Ignition. The White Box was developed as the culmination of a nationwide craft brewery campaign that targeted the top 200 craft breweries in the country. The goal was to show off the power of Ignition on a self-contained White Box in an unobtrusive, plug-and-play installation on a bottling or canning line.

      8 min video

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      customer project Food and Beverage

      Ignition Solves 11 Key Problems

      Thanks to the Ignition implementations, now the plant operator has all the information and control that he/she needs in only one easy-access and high-reliability system. Also, laboratory, supervision and management personnel have access to historical and real-time production data, production quality, historical users’ operations, and a high quantity of reports that make the decision-making process easier than before.

      5 min video

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      customer project Food and Beverage

      Greater Access to Data with Ignition

      The bottling line and racking line application allows operators to select brands, tank sources and pathways to bottle beer from. Through Ignition scripting, the application checks whether the tank is ready and meets requirements for bottling and racking.

      6 min video

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      customer project Agriculture

      KTrack Helps Grain Facilities with Traceability & Inventory

      KTrack helps grain elevators meet traceability requirements and improve inventory management. KTrack is software from Konnection, a division of Kasa Controls & Automation. Konnection provides automation, data collection and other software solutions across many industries, including grain handling. KTrack is Konnection’s first off-the-shelf product offering. It’s an untraditional Ignition project in that there are no devices, PLCs, motors, or sensors to control; there are only a few memory tags.

      5 min video

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      customer project Mining

      Ignition Enables Data Collection, Analysis, and Much More

      Ignition is being used as an Industrial Information System and allows Constancia to obtain KPIs for daily production, maintenance, downtime, and equipment operation. It helps the production team to quickly find problems that prevent it from achieving optimal production.

      6 min video

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      customer project Manufacturing

      Greater Mobility, More Data, Less Paper

      The project was aimed at quickly collecting work-order data from the shop floor and communicating it to the company’s ERP system. The goal was to react faster to delays or unforeseen events. To accomplish that it was necessary to adopt a scheduling process supported by software, to give operators an integrated system to collect data on mobile devices.

      7 min video

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      customer project Aerospace

      Control Systems Upgrade for NASA Space Simulator

      This was a control systems upgrade for the space simulator, which is a joint venture of the National Aeronautics and Space Agency (NASA), the Jet Propulsion Laboratory (JPL), and the California Institute of Technology.

      7 min video

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      customer project Containers and Packaging

      Ignition Addresses Numerous Issues, Saves Money

      With Ignition, one person was able to create all the screens, in addition to his regular workload. No integrator was needed. Numerous projects were done using concepts of high-efficiency HMI including sparklines, analog indicators, radar plots and varying screen levels.

      7 min video

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      customer project Energy

      Ignition Improves Nuclear Measurement System

      This device runs 24/7, gathering measurement data from two types of detectors that measure radioactivity in the area. It performs sophisticated spectroscopic analysis on the measurements, which both identifies what radioactive isotopes are producing the radiation and how intense the activity is. This data is then sent back to our Horizon supervisory software for recoding in the historical database and display of alarms and data to the user.

      6 min video

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      customer project Food and Beverage

      Developing Dynamic Material Management in Ignition

      Pinnacle Foods Group requested a batch-driven method for ‘kits’ to be created, inventoried, and consumed into the production batch. Every ingredient is required to be traced from the warehouse, to the kit, and into the batch. The material management system includes barcode-based scanning and printing, allergen compatibility control, and dynamic inventory management.

      6 min video

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      customer project Transportation

      Safer Roadways with Active Warning System

      The RIAWS (Rural Intersection Active Warning System) project was conceived as a means to reduce the speed of vehicles on the main road as they enter a rural intersection where there is another vehicle approaching from a side road that presents a potential collision hazard.

      6 min video

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      customer project Construction Materials

      Building Materials Facility Goes 3D with Ignition

      We wanted to validate that we could write a 3D CAD application under the Ignition platform. The MineCAD application was selected for this project. This application is currently used by the quarry manager at the plant to validate the mining blasts chemistry, to refine the quarry model, and to update the topography. The biggest challenge on this project was to implement and use the JavaFX API with Ignition. With the help of Inductive Automation, a new Ignition component was created and added to the designer.

      7 min video

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