Upgrades for Existing Water Systems
We review the sites, instruments, control logic, communications, and operator needs before planning an upgrade. The work may involve individual panels, a new HMI, or controls and communications across the field system.
A utility may need to connect a remote well, replace pump-station controls, or bring several facilities into a common operator view. We identify which equipment can remain and where changes are needed, then plan the field work and software changeover around the utility's operating requirements.
Water and Wastewater Systems in Arizona
Our office is in Mesa, and much of our water work is in Arizona. For the Town of Snowflake, GDS connected four wells and the wastewater treatment plant to a VTScada station at Town Hall, with text-message alarms and cellular remote access. At a private utility's wastewater plant, we replaced a mid-1990s Intellution FIX32 HMI with redundant VTScada servers, running both systems in parallel until the plant was working on the new application.
We built the operator interface and pump controls for an Army National Guard water treatment plant in northern Arizona. Since 2021 we've also maintained the Motorola MOSCAD and ACE3600 RTUs and radios for a private water company, in towns including Sedona, Miami, Casa Grande and Bisbee.
Wastewater Treatment Controls
At the wastewater treatment plant in Sidney, Ohio, GDS replaced the SLC 500 PLCs at the raw pump station and blower building with CompactLogix 5380 controllers. Conversion modules kept the existing field wiring in place, and we updated the plant's Wonderware communications for the new controllers before the January 2026 cutover.
PLC and RTU Programming
GDS installs and programs controllers for treatment plants, distribution systems, wells, tanks, and pump stations. Our application work connects field inputs and outputs with the control logic, equipment status, and alarms operators need. We review existing programs when expanding a system so new controls fit the way the utility operates.
Our controller experience spans Motorola's RTU line, including Intrac, MOSCAD, ACE3600, and MC-Edge, as well as Allen-Bradley, Modicon, Moxa, and AutomationDirect PLCs. Nixa's twelve-site upgrade combined PLC programming, cellular communications, and VTScada. At Magna Water District, our hardware integration work included CompactLogix controllers and Point I/O, coordinated with a separate software integrator.
Control Panels and Instrumentation
We design and build control panels for new installations and existing equipment upgrades. Panel work includes controller and I/O selection, power components, equipment layout, wiring drawings, and connections to field devices. Flow meters and other sensors supply measurements to the control system; each signal should read the same in the controller and the HMI.
Radio, Cellular, and Ethernet Communications
Our RF engineering services include path surveys, radio network design, and FCC licensing work. Communications options include licensed VHF, UHF, and 800 MHz radio, digital trunked networks, cellular modems, and Ethernet. Selection depends on the installed equipment, site geography, available infrastructure, and the data each location needs to exchange.
We coordinate communications changes with controller and HMI work so the field sites and operator software are configured together. Testing includes the data exchanged between those parts of the system.
VTScada and Ignition Development
Our application work can include site graphics, alarms, historical data, reporting, and remote access. We work with the utility to establish the required operator functions and acceptance tests before implementation. Our engineers also support Wonderware (AVEVA InTouch) and older Intellution iFIX and Proficy systems, and our team includes an Ignition Core Certified engineer.
For Medina County, GDS replaced Wonderware with VTScada while retaining the existing Motorola RTUs and communications. That project included redundant servers, workstations, alarms, history, and reporting. So an HMI replacement can be scoped separately from new field controllers.
Network Design and Operator Access
SCADA network design also addresses segmentation and access to operator software. We review remote-access requirements with the utility and coordinate the controls network with its IT requirements. We include user permissions and remote access in the engineering scope.
Commissioning, Documentation, and Support
Installation coordination, testing, and commissioning carry the design into the field. We provide panel and application documentation and operator training as part of the agreed scope. After installation, GDS supports troubleshooting, maintenance, and future changes to controllers, communications, or software, with after-hours support available for contract customers. The utility receives records that help its operators and maintenance staff understand the installed system.
Common Questions
- Does an HMI upgrade require new RTUs at every site?
- Not necessarily. At Medina County, GDS replaced Wonderware with VTScada while retaining the existing Motorola RTUs. We check protocols, firmware, tag mappings and communications before deciding which field equipment can remain.
- How do you choose between Motorola RTUs and Allen-Bradley PLCs?
- The decision depends on the installed system, I/O, communication methods, control requirements and the utility's maintenance standards. GDS has project experience with both. We review those constraints before recommending a controller or a phased replacement.
- How can remote wells and pump stations connect to SCADA?
- Options include licensed radio, cellular and Ethernet where suitable infrastructure exists. A site review considers terrain, coverage, power, antenna locations and the data exchanged. The design also defines what the controller and HMI should do when a connection is lost.
- How is a field conversion planned around operations?
- We establish site access, backups, staffing and acceptable outage windows with the utility. A conversion plan identifies the work sequence, checks required before returning equipment to service, and the steps to restore the previous configuration if a problem prevents acceptance.