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InduSoft Web Studio (IWS) made

upgrading from a system installed

almost 10 years prior extremely easy.

InduSoft Web Studio proved to be

the ideal solution for the current

requirements and planned future

upgrades of the Lake County

Public Water District.

The developer found IWS very

intuitive, straightforward, andeverything proceeded with

a minimum of time spent in

additional development.

BackgroundMunicipal water districts are integral aspects o theinrastructure o any city. Water and wastewatertreatment are absolutely vital or any city, and inorder to meet both state and ederal regulations, watertreatment must be careully monitored. From thewater source to the tap, there is a complex processthat city water supplies must go through to maintainsaety and reliability. Oversight o the process is animportant way to ensure that water supplies make itthrough the entire process while adhering to health

and saety regulations and reliably providing water toa large number o residents.

Te Lake County Public Water District, which servesthe City o Zion, the Village o Winthrop Harbor andthe Illinois Department o Natural Resources (IllinoisBeach State Park and North Point Marina) on a non-prot basis, recently ound their system in need oan upgrade. B&W Control Systems Integration waschosen or this large municipal project.

B&W Control Systems Integration specializes inmunicipal clientele and does everything rom acilityautomation to water and wastewater SCADA andremote SCADA applications. Te Lake County water/wastewater treatment SCADA application was builtusing InduSot Web Studio, and it presented B&Wwith an opportunity to work with new SCADAdevelopment sotware.

Te ChallengeTe application monitors a water treatment plant that

services Zion, Illinois, among other nearby towns. Teplant pumps in water rom Lake Michigan. Low litpumps bring water into the plant, and then take it tothe main water acility where it goes through threedierent clariers. During this stage o the process,

Lake County Public Water District Grows With the Help

of B&W Control Systems Integration and InduSoft

Upgrades to Lake County Public Water District SCADA system added

redundancy, remote monitoring, and current PLC communications

Figure 1: Clear, inormational and easy to use interace or pump house monitoring


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mixers, water levels, pumps, valves, and equipmentailures are all monitored by the SCADA system. Teclariers eed the water through our dierent lters.Here, the application monitors and records data suchas water levels, pump and valve activity, the backwashprocess, and the time the water spends in each step othe process. Te water is ed into the clearwell wherethree high service pumps move it into a large storage

tank. Te application keeps track o the water ow ineach stage o the process, and also monitors the mainstorage tanks.

Te largest challenge o the project was the upgrade oequipment. Lake Countys current architecture madeuse o outdated PLCs with proprietary protocols. Forthe new system, Allen Bradley Control Logix PLCswere employed in a massive upgrade plant wide. Tisnew upgrade would take the plant rom producing4.5 million gallons o water per day to producing 6.5

million gallons per day.

Another unique challenge o the project included theneed or remote process monitoring to help keep the

Continued from front page...

Figure 2: Overview screens oer a real-time view o the process.

plant active at all times. Te upgrade required that B&Wincorporate a remote SCADA solution. An additionalrequirement or the project included adding redundancymeasure to ensure that the plant remained online in theevent o a hardware ailure.

Te current SCADA sotware used by Lake County wasInduSot Web Studio v4.0. Te developer who worked othe project, Jim Gramhoer, was tasked with upgrading aunamiliar SCADA system using a newer iteration o thesotware, with new PLCs and additional tag requirementTe SolutionTe upgrade or Te Lake County Public Water Districtwas able to incorporate all the unctionality o the originasystem, and introduce the new eatures necessitated or thupgrade. B&W developer Jim Gramhoer said, Upgradinthe InduSot application went perectly. We only had toinstall the new sotware, copy the data over and plug in th

new inormation, and everything went o without a hitch

Te upgrade brought the application rom version 4.0 oInduSot Web Studio to v7.0. InduSot develops new version

Figure 3: Discharge pressure and ow rates are shown as 24trends, and current values are displayed allowing operators tmake inormed decisions.


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o the sotware with compatibility in mind, meaning thateven applications developed in the rst iteration o InduSotWeb Studio can still be developed in the newest version. Tisallows plant owners to upgrade equipment such as PLCs andcomputers with the assurance that development time usedto create the original application or the system is not lost.Integration can be perormed easily or upgrades because theapplication will still be compatible with the new sotware.

Another benet o using InduSot or the upgrade was

Figure 5: Clarier status is monitored and displayed on arepresentation o the physical layout. Efuent and inuent valvestatus, along with mixer RPMs are monitored closely.

the act that the drivers required to connect with thenew Allen Bradley PLCs are native within the sotware.No additional modules or protocols needed to bepurchased to connect directly with the new hardware.

B&W added some redundancy eatures to the systemduring the upgrade. Beore, the InduSot Web Studiobased SCADA system resided on one server. Tenew architecture includes two rack servers that actas a redundant pair. Te licenses included with theseredundant servers also oered Lake County twoadditional remote thin client viewers that clients can usto connect to the system.

Tis web connectivity was a great addition to theupgrade. With the thin client viewers, the plantoperators and supervisors can monitor the processrom remote locations, such as ofces or homes. Tisensures that its easy to take the SCADA system withthe personnel wherever they go, and helps ensure thatalarms are addressed as soon as possible. Tis improvesthe saety and reliability o the system, and reducesdowntime in a critical municipal utility.

One aspect o the upgrade that went especially wellincluded the changing o tag names to include more

Upgrading the InduSot

application went perectly.

We only had to install the

new sotware, copy the data

over and plug in the new

inormation, and everything

went o without a hitch. Jim Gramhoer, B&W Developer

Figure 4: Te historian screen provides quick access to loggedvalues back to any time or date. Clicking on the trendprovides instant access to all the recorded values or thatperiod.


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2011 InduSoft, Inc. The InduSoft logo is a registered trademark of InduSoft, Inc. All other products or services are trademarks of their respective companies.

For more information contact your local distributor or InduSoft directly at

[email protected] or 877-INDUSOFT (877-463-8763) or 512-349-0334.

Figure 6: Clearwell levels, and set point are adjusted and monitored.Clear layouts reduce operator errors.

descriptive titles. According to Gramhoer, Te oldsystem tags were cryptic, and the ability to go in andchange tag names without disrupting anything wasreally useul. I havent seen this in any other SCADAsotware solutions.

Te ResultTe smooth transition between the upgrade process oequipment and sotware went exceptionally smoothly.Te project requirements were met with a minimumo time spent in additional development. Gramhoer,who was new to developing in InduSot Web Studiosaid Its easy to work with InduSot rom the verybeginning, and very intuitive. Te development wasstraightorward, and even without the class, its easy to

pick up the sotware very quickly.A key point that B&W noted in working withInduSot Web Studio was the rich eature set that

Figure 7: Filter Control, PID set points, and valve status are allobserved and adjusted rom a convenient location, with real-time

eedback.

comes included with the sotware solution. BecauseInduSot Web Studio can perorm all the necessaryunctions o a SCADA sotware and includes allthe tools without requiring additional add-ons andmodules, its the ideal solution or any SCADA

integration client with a xed budget. Te LakeCounty Public Water District intends to continueusing InduSot Web Studio or uture upgrades, and isplanning on upgrading to a higher tag count very soonas they continue to modiy their current architecture.

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