Project G

Project Report: SCADA System Replacement and Feature Integration

1. Project Overview  

This project is currently ongoing and involves the replacement of all existing old SCADA visualization systems with a fully developed and customized PcVue-based SCADA platform.

The new system will be designed, developed, and implemented in collaboration with the client, with regular project review intervals to incorporate feedback, add new features, and refine system functionality as required and approved throughout the development process.

The new SCADA platform will be built to replicate all existing functionality while introducing enhanced operational capabilities, modern design standards, and long-term maintainability. 

2. Project Objectives 

• Replace the existing SCADA visualizations with a new, unified PcVue SCADA system. 
• Obtain copies of the latest PLC and SCADA programs to support accurate and efficient system redevelopment.  
• Ensure the new system is fully integrated alongside the existing SCADA without any plant downtime during transition. 
• Provide enhanced visualization, control, and alarm management features. 
• Deliver comprehensive training and documentation to allow in-house management and modification. 

3. System Development and Integration 

The new PcVue SCADA system will be developed and tested in parallel with the existing installation.

This approach ensures that the main plant operations will not experience any downtime during the transition phase.

Once development and testing are complete, the new SCADA system will be seamlessly integrated into the live plant environment, after which the existing HMI/PC and legacy visualization components can be safely decommissioned and removed. 

All system data, configuration files, and process logic will be fully replicated and validated to guarantee functional equivalence before cutover. 

4. System Features and Enhancements 

Alongside the replacement SCADA system, several enhanced features will be implemented to improve operational visibility, reliability, and maintainability. 

4.1 PcVue SCADA System 

The PcVue SCADA platform provides a robust, flexible, and scalable environment capable of integrating multiple PLC systems and process areas.

Its open architecture supports custom graphics, real-time trending, alarm management, and advanced user permissions, ensuring long-term adaptability to future plant expansion.

4.2 Alert™ Alarm Management System 

The new system will include full integration of Alert™, a proven Alarm Management System already deployed across other biogas facilities.

Key benefits include:

• Real-time alarm and event notifications via SMS or voice call. 
• Customizable alarm thresholds and escalation paths.
• Comprehensive event logging for analysis and reporting. 

Both the PcVue SCADA and Alert™ systems are supplied with lifelong licenses, allowing full in-house editing, modification, and expansion as required by the client. 

5. Training and Handover 

Comprehensive operator and maintenance training will be provided to ensure that plant personnel are fully confident in using, maintaining, and modifying both the PcVue and Alert™ systems.

This includes:

• Training sessions covering configuration, alarm management, and visualization tools. 
• Guidance on editing and adding new tags or process elements. 
• Documentation and backup procedures for future system updates. 

6. Conclusion

The replacement of the old SCADA systems with a PcVue-based platform will deliver a modern, flexible, and maintainable control solution.

By integrating Alert™ for advanced alarm management and ensuring full compatibility with existing PLC infrastructure, this project provides long-term operational resilience and improved control capabilities — all achieved with zero production downtime during implementation.

This upgrade demonstrates our continued commitment to providing secure, scalable, and user-friendly automation systems that empower operators and streamline plant operations.