Madison Metropolitan Sewerage District

As a wastewater treatment facility, the Madison Metropolitan Sewerage District (MMSD) faces several unique challenges:

• High pumping costs – Due to its location and terrain, the facility cannot rely on gravity like most plants. All wastewater must be pumped both to and from the plant.
• Stringent phosphorus limits – Wisconsin’s regulations are more restrictive than in most states, requiring additional infrastructure to treat water.
• Extensive off-site responsibilities – MMSD manages approximately 40 pumping stations owned by other municipalities or sanitary districts. These are scattered across the greater Madison area in locations without cellular or Internet connectivity, requiring radio communication to receive live operational data. When issues arise, crews must be dispatched to confirm that stations are functioning correctly.

In the 1990s, MMSD installed its first SCADA system, which used serial communication with controllers. This system served the district well for two decades but had become obsolete as both hardware and software approached end-of-life. MMSD also needed operators to be able to access the system from any location. In the early 2010s, the district began searching for a new system that could integrate legacy elements while providing the best fit for its evolving operational needs.

The decision ultimately went to GENESIS64 for several reasons:

• The Mitsubishi Electric Iconics Digital Solutions team demonstrated the platform’s ease of use and rapid setup, outperforming competitors
• The modular, open architecture provided the flexibility needed for creative, efficient design
• The cost fit within the district’s budget
• Jim Sulzer of Sulzer Consulting, LLC and Russ Ropken of RSI Company - Automation Development and Consulting offered hands-on support, helping MMSD quickly get up to speed with the software

Taken together, these factors made GENESIS the best value and the right choice for MMSD’s next-generation SCADA system.

• GENESIS64™ HMI/SCADA Suite
• Hyper Historian™
• GraphWorX™64
• GridWorX™
• AlarmWorX™64
• AlertWorX™
• CFSWorX™
• Asset Navigator

The Madison Metropolitan Sewerage District (MMSD) has greatly benefited from Mitsubishi Electric Iconics Digital Solutions’ GENESIS platform. The facility manages:

• 5,000 assets
• Approximately 40,000 process tags
• 6,000 alarms
• 5,000 historical points

Because the platform provides critical real-time operational data, the MMSD team can quickly identify and resolve issues to keep the facility running at peak performance. Operators can also access events, alarms, and detailed operation and maintenance records—directly contributing to a more efficiently run facility.

With its advanced customization capabilities, GENESIS64 enables the MMSD team to easily add and modify system features as needed. This capability is especially valuable since the facility typically has just one operator on duty 24/7 to oversee a very large system.

GENESIS64 helps prevent operator overload by sending different data streams in different directions. For example, when maintenance workers are in the field performing tests, they can access the specific information they need to address issues on the spot. Operational efficiency has also improved by integrating GENESIS64 with external systems. MMSD’s Computerized Maintenance Management System (CMMS) database controls all work orders and maintenance history. Now, operators can:

• Pull up a piece of equipment and view its history
• See past maintenance work and who performed it
• Check for any open jobs
• Access other relevant details in one place

This integration saves time and ensures maintenance records are always accurate and up to date.

The MMSD has also gained secure remote access. The process control system is locked down with Citrix technology combined with GENESIS’s inherent high-level security. Operators can securely log in from tablets, phones, thin clients, or computers, while supervisors can access the system from home to respond quickly to issues. In an era of constant cyber threats, this robust security is essential for both the MMSD’s IT department and the facility’s role as a public utility.

The Madison Metropolitan Sewerage District uses GENESIS64 to serve its communities at the greatest level. Mitsubishi Electric Iconics Digital Solutions’ agile GENESIS platform with its flexible customization capabilities has been particularly helpful and convenient to the facility’s team.

Operators can more easily access information for quick action to resolve issues. Moreover, its engineering team can use the information obtained through GENESIS to plan for future upgrades. On top of this, the facility has secure remote access that provides better protection. To date, the MMSD has been running GENESIS for almost ten years and will continue to do so in the future.