Ignition SCADA Wash Plant Upgrade /
Project Overview
Onslow Salt engaged Tier16 to modernise the SCADA system controlling its wash plant, replacing Wonderware InTouch with Ignition, and redesigning the OT network architecture to achieve stronger IT/OT separation. The upgrade combines a modern SCADA architecture with high-performance HMI design to give operators clearer visibility and control of the process.
Client Challenge
The client needed a modern SCADA environment that improved reliability and gave operators clearer situational awareness. Four main drivers shaped the project:
Platform age and support: Ageing software and supporting legacy infrastructure often leads to rising support effort, limited options for expansion, and increasing exposure to unplanned failure on a system the plant depends on.
OT security: The client needed a segmented architecture that protects the control system from the wider corporate network, while still allowing the controlled data flow the business requires.
Reliability: A critical production asset needs a SCADA platform with resilient, redundant architecture, so that a single server failure does not leave operators without visibility or control.
Operator effectiveness: Legacy SCADA screens often present large volumes of data, making it harder for operators to separate normal operation from developing problems.
The client wanted an interface built around abnormal situation management, where the operator’s attention is drawn to what matters, when it matters.
Tier16 Solution
Tier16’s solution migrates the wash plant SCADA from Wonderware InTouch to Inductive Automation’s Ignition platform, providing a modern and more resilient SCADA architecture.
The new operator screens apply high-performance HMI design principles, guided by the Abnormal Situation Management (ASM) philosophy. The aim is to help operators recognise abnormal conditions earlier and respond with confidence.
To manage transition risk, the new Ignition system is tested and validated side by side with the existing InTouch system. This allows operators and engineers to confirm the new system’s behaviour against live plant conditions before cutover, protecting operational continuity.
Technologies Used
Project Outcomes & Impact
In a continuous process like the wash plant, the earlier an abnormal condition is recognised, the easier it is to correct before it affects throughput, equipment health, or the safety of personnel on site. The upgrade is built to deliver:
Stronger reliability and performance across wash plant control.
Improved operator situational awareness through ASM-guided, high-performance HMI screens.
Strengthened network security with improved IT/OT separation.
Greater operational visibility across the wash plant.
Minimal transition risk, with the new system validated against the existing one before cutover.
A modern SCADA platform positioned for future expansion and integration.
