Challenges

1. Vendor Lock-In and Fragmented Tooling:

The municipality’s existing setup involves multiple Rockwell Automation PLCs, each requiring different software tools and licenses for programming and maintenance. Engineers need to install and maintain up to 15 separate software packages per workstation, leading to inefficiencies, high costs, and an increased risk of errors due to version mismatches.

2. Inadequate Data Infrastructure:

The control systems rely heavily on a SCADA system using vendor-proprietary drivers, creating a vendor lock-in situation. This means that if the SCADA system fails, the entire data infrastructure collapses, leaving the municipality vulnerable to significant operational downtime.

3. Lack of Code Standardization:

The existing PLCs cannot efficiently share or standardize code across different pump stations. Importing and exporting programs require manual intervention and conversion tools, increasing the likelihood of errors and extending the testing process.

4. Data Loss and Slow Execution:

Regular data loss is a significant issue due to the lack of local data buffering during internet outages. Additionally, the system operates at slow speeds (250ms+), which hinders real-time responsiveness and reduces overall system efficiency.

5. Absence of Version Control:

The municipality has no centralized version control system, resulting in inconsistent library versions across different stations. Updates are manually implemented, further complicating the maintenance process and increasing the risk of errors.

How OTee helps solve these challanges:

1. Eliminating Vendor Lock-In with Virtual PLCs:

OTee provides a virtual PLC solution that seamlessly takes over the I/O from the existing Rockwell PLCs. This deployment removes the dependency on proprietary tools and vendor-locked infrastructure, enabling the municipality to transition to an open-standard architecture based on modern publish-subscribe (Pub-Sub) data models.

2. Unified Data Infrastructure:

By adopting OTee’s platform, the municipality implements a robust, out-of-the-box infrastructure built on open standards like OPC-UA. This architecture replaces the need for an infrastructure centralized around a proprietary SCADA system, ensuring that data flow remains uninterrupted and flexible, even in the event of system changes.

3. Code Standardization and Compliance:

OTee standardizes the PLC programming across all facilities, adhering to the IEC 61131 international standard. This allows for seamless program import/export across different devices and locations, significantly reducing the need for manual interventions and enabling rapid deployment of new automation logic across all pump stations.

4. Enhanced Reliability and Data Integrity:

OTee’s platform ensures that all PLCs buffer their local data, which is then forwarded to an online MQ broker with queuing capabilities. This setup effectively mitigates data loss during connectivity issues, ensuring that no critical operational data is lost, even during prolonged outages.

5. Improved Speed and Performance:

The virtual PLCs operate at speeds around 100x faster than the previous setup, creating the premises for enhanced sampling rates and control loops.

6. Centralized Version Control and Fleet Management:

OTee integrates a Git-based version control system that allows centralized management of all libraries and program versions. This feature streamlines updates and ensures consistent operation across all pump stations, enhancing overall system reliability and reducing maintenance efforts.

Benefits

By implementing OTee’s IIoT cloud platform, the water treatment municipality achieves the following benefits:

• Cost Reduction: Eliminates the need for multiple software licenses and reduces engineering time spent on managing different PLCs and their environments.

• Increased Uptime: Enhances data reliability and system performance, minimizing downtime and ensuring continuous operation.

• Operational Efficiency: Standardizes and streamlines PLC programming, allowing rapid deployment of updates across all stations.

• Scalability: Enables the deployment of master PLCs and automation logic across the entire infrastructure, facilitating easy scaling of operations as needed.

• Future-Proofing: Transitions to an open, vendor-agnostic architecture that supports modern IT workflows and prepares the municipality for future technological advancements.