How Wheeler Ridge Upgraded SCADA for Unmatched Efficiency

1. Company and SCADA Project Overview

Background
Wheeler Ridge-Maricopa Water Storage District is responsible for managing a 230-square-mile region encompassing 147,000 acres of farmland in the Southern San Joaquin Valley, serving many farms. The district supplies water to its users through two primary sources: the California Aqueduct and independently managed groundwater wells. To efficiently support these operations, a network of 34 pumping plants, monitored by a Supervisory Control and Data Acquisition (SCADA) system, distributes water via pipelines and canals, with usage carefully metered for monthly billing.

Project Motivation
Originally installed in 2000, the District’s SCADA system had become outdated and increasingly unreliable, necessitating a comprehensive upgrade. Frequent technical failures, communication disruptions, and limited support prompted the District to pursue a new SCADA solution that would modernize operations, reduce maintenance, and enhance service reliability.

2. Problem Definition

Key Challenges

• System Performance and Data Delays: The old SCADA system lacked real-time data capability, leading to response delays and increased manual intervention by operators. This data lag often hindered timely decision-making, particularly during peak summer months when demand was highest.
• Communication Failures: Frequent “comm fails” disrupted operations and required technicians to spend time on-site for repairs, adding considerable labor hours and travel costs. These issues were often discussed at board meetings, highlighting the impact on both operations and budget.
• Vendor Support and Cost: Support from the previous SCADA vendor was costly and infrequent, with each remote service call costing between $400-$500. Monthly costs often exceeded $1,000 due to these recurring incidents. As vendor support became less responsive, maintenance costs and system downtime continued to increase.

Interim Solutions
To manage these limitations, District staff relied on temporary fixes, such as manual equipment resets and frequent site visits to address system lags. However, these workarounds proved unsustainable, increasing labor costs and diminishing overall efficiency.

3. Decision-Making and Solution Selection

Selection Criteria
In choosing a new SCADA solution, the District prioritized:

• Real-time data capabilities for improved automation and response
  
  
• Reliable communication systems with redundancy to minimize failures
  
  
• Streamlined support from a provider familiar with district operations

Process
The District considered various vendors but ultimately selected Avadine due to an established, positive working relationship through the utilization of Avadine’s water information platform Latis. Feedback from neighboring districts and Avadine’s demonstrated expertise with water management systems aligned well with the District’s needs.

4. Implementation Process

Execution Strategy
Avadine’s team managed the implementation to minimize disruptions and maintain water service. The upgrade began with the District’s most problematic system, known as the “5-system,” a complex area with frequent technical issues. To ensure continuity, the legacy SCADA system remained operational until each new component was fully ready. Once prepared, cutovers were completed in carefully scheduled intervals, with initial system cutovers taking approximately two and a half days and subsequent cutovers requiring only 4-6 hours.

Challenges and Solutions

• Infrastructure Overhaul: Outdated wiring and components required extensive clearing to make room for new equipment. Avadine and District staff cleared truckloads of old wiring and reorganized equipment, transforming the control centers to support the new system.
• System Configuration: Avadine’s team worked closely with District staff to fine-tune the system’s programming, replacing the previous scheduling model with real-time tank levels and flow controls. This required extensive testing, including a mock setup in Avadine’s lab, to ensure the system met performance standards.
• IT and OT Collaboration: Avadine and the District’s IT team coordinated closely to resolve any potential compatibility issues, ensuring the smooth integration of operational technology with existing IT systems.

5. Technical Architecture and Components

Key System Components
The upgrade included a robust set of Opto 22 hardware, and the Ignition by Inductive Automation software platform, enabling reliable control and data handling. Critical components included:

• Opto 22 GRV-EPI-PR2 Processor: Central processing for enhanced system control
  
  
• MultiTech LTE Gateways with LoRaWAN: For reliable wireless connectivity across pump stations
  
  
• Canary Historian: For predictive maintenance and data logging to improve operational planning
  
  
• Ignition by Inductive Automation: A powerful SCADA and HMI platform enabling real-time monitoring, data visualization, and seamless system integration for enhanced operational control.

Security Measures
To address cybersecurity, the District implemented VPNs, firewalls, and segmented networks, enabling remote monitoring without risking system integrity. A layered security approach using jumper servers minimized the risk of unauthorized access and ensured secure remote troubleshooting.

6. Results and Impact

Operational Improvements
The new Ignition SCADA system has delivered several key improvements:

• Reliability: The upgraded system’s triple redundancy has virtually eliminated comm fails, providing uninterrupted data access and greatly reducing the need for manual resets or interventions.
  
  
• Efficiency Gains: Transitioning from a scheduled operation to real-time tank level management allowed for more efficient use of pumps. This reduced wear on high-power pumps, optimized energy use, and improved water flow stability for District users.

Cost and Time Savings

• Energy and Maintenance Savings: Reducing the start-stop cycles of large pumps has significantly lowered energy costs and extended equipment life.
  
  
• Support Cost Reduction: Monthly support costs have decreased substantially due to reduced service call requirements.

7. Customer and Stakeholder Feedback

Positive Stakeholder Response
Feedback from stakeholders, including board members and water users, has been overwhelmingly positive. One board member, a landowner within the District, noted a marked improvement in service reliability and reduced manual interventions by his team. The upgraded system’s stability and efficiency have minimized disruptions, contributing to higher customer satisfaction.

8. Future Prospects

Enhancement Opportunities
Though physical expansion is not feasible, the District anticipates potential SCADA enhancements, such as:

• Predictive Maintenance Sensors: The District plans to add vibration sensors for early issue detection on pumps.
  
  
• Mobile Access for Select Staff: Limited mobile access could improve operational flexibility, allowing supervisors to monitor system status remotely.

9. Lessons Learned and Recommendations

Key Takeaways

• Efficiency through Real-Time Data: Replacing scheduling with real-time operation allowed the District to automate more effectively and reduce dispatch workload.
  
  
• Importance of Redundancy: Implementing triple redundancy proved essential in minimizing comm failures and ensuring operational continuity.

Advice for Similar Districts
For other districts considering a SCADA upgrade, the District advises a thorough needs assessment and engaging with nearby districts for insights. By identifying essential features early, the District ensured the new system met specific operational requirements, setting a strong foundation for future scalability and efficiency.

10. Operational and Business Metrics Impact

Business Impact Summary
The SCADA upgrade to Ignition has driven measurable cost savings and efficiency improvements:

• Reduced Manual Intervention: Fewer comm fails have saved 2-3 hours per incident, lowering fuel costs, labor hours, and vehicle wear.
  
  
• Cost Reduction in Support Services: With fewer comm fails, support expenses have decreased significantly.
  
  
• Improved Financial Stability: The upgrade reduced board-level concerns about recurring operational costs, resulting in more predictable financials and enhanced operational reliability.

This business case demonstrates how Wheeler Ridge Maricopa Water Storage District’s SCADA upgrade with Avadine resulted in significant operational enhancements, cost reductions, and a streamlined, future-ready water management system.

11. Technical Partners