Actemium partnered with a municipal wastewater treatment facility in Southeastern Michigan to modernize its aging SCADA infrastructure. The existing system relied on obsolete and unsupported technologies that no longer met operational, cybersecurity, or regulatory requirements.
Actemium implemented a fully redundant, secure, and scalable FactoryTalk View SE–based SCADA architecture, improving system stability, strengthening security, simplifying reporting, and creating a sustainable platform for long-term operations.
BACKGROUND & CHALLENGE:
The facility’s legacy SCADA system had exceeded its usable life and posed increasing operational and compliance risks. Key challenges included:
- An HMI developed in Visual Basic 6.0, unsupported since 2008
- Outdated communication protocols and legacy Wonderware Historian servers
- Limited vendor support and elevated cybersecurity exposure
- Custom reporting built on obsolete ASP frameworks
These limitations increased vulnerability to system failures, complicated regulatory reporting, and drove up maintenance costs. Without modernization, the facility faced growing risks related to downtime, compliance gaps, and system obsolescence.
APPROACH & SOLUTION:
Actemium served as the single-source automation partner, providing end-to-end delivery from design through deployment. The team engineered a modern, redundant SCADA system tailored to the facility’s long-term needs.
Key components included:
- Primary and secondary SCADA servers with automatic failover
- Ten desktop and panel-mounted HMIs for distributed operations
- Direct PLC communication via RSLinx and RSLinx Gateway
- Redundant SQL Server databases for secure historical data storage
- Dream Report for automated reporting and scheduled distribution
- Win911 for automated alarm notifications via voice, text, and email
- New PLC panels with encrypted cellular communication across 13 remote metering stations
- Custom PLC logic for multi-day data buffering and synchronization during outages
Actemium also handled system startup, validation, testing, and delivery of complete documentation and training materials. This integrated approach ensured consistent quality, reduced risk, and enabled seamless coordination across all project phases.
RESULTS:
The modernization project produced measurable operational and strategic benefits.
Improved Reliability & Performance: Redundant servers and modern PLCs reduced downtime and improved responsiveness.
Enhanced Cybersecurity: Obsolete systems retired; encrypted communications strengthened network protection.
Stronger Regulatory Compliance: Automated reporting and secure historical data improved audit readiness.
Improved User Experience: Modern HMIs simplified operations and reduced workload.
Long-Term Sustainability: Scalable platform eliminates reliance on unsupported technologies.
The upgraded system enables plant personnel to respond more quickly to operational issues while reducing overall risk.
Ready to Modernize Your Operations?
If your facility is facing challenges related to aging control systems, cybersecurity risks, or reporting inefficiencies, Actemium can help. Contact our team to learn how we can support your modernization and digital transformation goals.
