Ignition SCADA + Templates+ LTE Connectivity Case Study
Executive Summary
Deep Blue, a rapidly expanding midstream produced-water operator, needed a unified and scalable operations platform to manage more than 80 diverse and geographically dispersed facilities—none of which had existing network infrastructure. Partnering with Deep Blue’s operations and IT teams, a field-wide CradlePoint LTE network was deployed, and a standardized cloud-based Ignition SCADA environment was built to unify workflows, simplify operator interaction, and enable centralized monitoring and control across all sites.
With a centralized KEPServerEX connectivity layer and structured MySQL data foundation, Deep Blue now benefits from rapid facility onboarding, improved visibility, consistent alarm management, automated reporting, and a scalable architecture that supports long-term growth and data- driven decision-making.
Project Overview
Deep Blue— A fast-growing midstream produced water company—was rapidly acquiring a diverse portfolio of nearly 80 remote facilities. To support their evolving operations model, Deep Blue needed a modern, unified control system that could scale quickly, standardize operator workflows, and support future growth.
The first major obstacle, a lack of network infrastructure to support any remote connectivity, had to be tackled quickly. Partnering with Deep Blue’s operations and IT teams, a standardized cloud-based Ignition SCADA system was deployed alongside a field-wide CradlePoint LTE network that became the backbone for secure and reliable connectivity across all sites.
The result: a future-proof operations platform enabling consistent functionality across all levels of an asset base, has assisted Deep Blue’s continued growth.
The Challenge
Although the sites performed similar functions, they varied significantly in control philosophy and equipment. Operators were required to manage multiple PLC configurations, site layouts, and control platforms while maintaining safe and efficient operations.
Key challenges included:
1. Network Infrastructure Across the Field
a. No fiber connectivity
b. No radio network in place
c. No standardized networking hardware
d. Deep Blue needed standardized network infrastructure to make remote operations possible. A communication system needed to be designed, deployed, and validated across the entire field.
2. Wide Variation in Site Complexity
a. The portfolio included:
i. Simple single-train SWDs
ii. Complex five-train facilities
iii. Disposal pits
iv. Transfer stations
v. Water handling facilities
b. Each site required unique control logic but a common operator interface.
3. Diverse PLC Platforms and Protocols
a. Facilities relied on a mix of:
i. Allen-Bradley CompactLogix
ii. Allen-Bradley ControlLogix
iii. IDEC-based control systems
iv. DirectSoft-based control systems
v. Modbus
vi. EtherNet/IP
vii. MQTT
viii. Proprietary configurations
b. To centralize operations, the SCADA environment needed to abstract these differences.
4. Secure Third-Party Data Sharing
a. Deep Blue’s business model required automated reporting and bidirectional MQTT communication with other parties.
The Solution
The engagement delivered a complete operational transformation built on three core pillars: network connectivity, standardized SCADA, and scalable data infrastructure.
1. Field-Wide CradlePoint LTE Network (Deployed by Deep Blue IT)
In collaboration with Deep Blue’s IT team, providing consulting and full validation support, a field-wide LTE network using CradlePoint was implemented, ensuring secure and reliable communication across all facilities.
This included:
- Testing CradlePoint LTE in a lab environment
- Working with Deep Blue to implement appropriate scan-rates
- Standardizing the polling structure to maximize facility uptime
This field-wide LTE infrastructure became the foundation that enabled centralized SCADA and remote operations.
2. Standardized Ignition SCADA Environment
A unified operator experience was delivered through:
- Reusable screen templates
- Consistent navigation, alarms, and workflows
- Flexible configuration options to reflect each site’s equipment
- A streamlined onboarding process for new facilities
Regardless of hardware or layout, operators now interact with the same familiar interface at every location.
3. Centralized Connectivity with KEPServerEX
To integrate the wide range of PLC platforms and protocols, KEPServerEX was configured as the central communications hub, enabling:
- Native Allen-Bradley connectivity
- Native DirectSoft connectivity
- Modbus and EtherNet/IP integration
- Reliable communication across LTE links
This layer abstracts hardware differences and provides consistent data to SCADA and reporting systems.
4. Structured Data Layer with MySQL
A centralized MySQL 8 database provides:
- Historical trending
- Alarm and event records
- Automated reporting
- Integration with partner systems
- A scalable foundation for future analytics
Implementation
Standardized SCADA Components
Configurable templates for tanks, pumps, motors, alarms, and process flows were built—each customizable per site while maintaining a unified user experience.
Communications Validation at Each Site
Each facility underwent the following validation steps:
- PLC communication testing
- LTE connectivity validation
- End-to-end SCADA control verification
Unified Alarm Modelling
A standardized alarm structure ensured:
- Consistent operator response
- Clear prioritization
- Reduced training requirements
Full Functional Testing Before Go-Live
All systems were validated for the following:
- Control accuracy
- Data integrity
- Remote access functionality
- Stable network performance
This standardized approach enabled efficient commissioning across dozens of unique facilities.
Results
Deep Blue now operates a modern, scalable, and fully connected control platform that supports both current operations and long-term growth.
Outcome
- Field-wide CradlePoint LTE network enables reliable, secure connectivity across 80+ sites.
- Standardized SCADA experience reduces operator training time.
- Rapid onboarding of newly acquired facilities using repeatable templates.
- Centralized visibility improves response times and operational decision-making.
- Automated reporting ensures accurate and timely data sharing with partners.
- Flexible architecture supports future expansion and analytic initiatives.
Deep Blue now has a unified operational foundation that empowers their team to scale rapidly, operate efficiently, and adapt to future business needs.
Conclusion
By building a field-wide CradlePoint LTE network and implementing a standardized cloud-based Ignition SCADA environment, Deep Blue Water transformed its facilities into a cohesive, modern, and scalable operations ecosystem.
This unified platform now supports Deep Blue’s vision for growth, efficiency, and data-driven operations well into the future.
Client Testimonial
“From day one of Deep Blue, PLC construction has been a valued and integral partner. No request has been too great or too small – whether it was building a SCADA system from the ground up, integrating a complex acquisition or simply building a report, PLC has been there for Deep Blue supporting our rapid growth with professionalism and integrity. They are a great partner to have!” – Brian Hoogendam, Chief Information Officer
