Waterloo, a regional municipality in southwestern Ontario, provides drinking water and wastewater treatment to over
While the existing system functioned, it lacked the advanced capabilities necessary for long-term efficiency, security and resilience. The scope of the project was significant: 157 facilities across a large geography and of varying sizes and complexity needed to be upgraded. However, modernising critical water infrastructure posed a unique challenge as these systems could not be taken offline without disrupting essential services.
The region of Waterloo required an integration partner that could navigate the technical and operational complexities while achieving continuous water availability. They sought a turnkey solution provider capable of both system integration and panel supply. Brock Solutions was selected as their partner, marking the beginning of a highly collaborative, multi-year transformation.
The solution was a phased, collaborative approach to water system upgrades. Brock Solutions leveraged its expertise in water and wastewater systems to create a tailored, phased approach to modernisation. Using Rockwell Automation technology, they developed standardised solutions for different facility types, delivering consistency across the entire network.
For smaller outdoor facilities, CompactLogix controllers with onboard I/O provided a streamlined and maintainable solution. Medium-sized sites used newer CompactLogix models, while the most complex facilities required ControlLogix controllers with full redundancy for reliability. Stratix switches, distributed I/O, and digital ring topology provided robust communication between systems. These standardised solutions enabled operators to work more efficiently across different sites, reducing downtime and improving issue resolution.
A key factor in the project’s success was continued stakeholder engagement. “Communication has been a key factor in the success of this project,” says Michael Rowinski, senior manager and technical lead at Brock Solutions.
From the outset, Brock Solutions involved operators, technicians and management in every phase of implementation. Weekly meetings, workshops, and hands-on testing sessions helped everyone, from seasoned operators with decades of IT experience to IT specialists securing the network, to have a voice in shaping the solution.
To mitigate risks during facility transitions, Brock Solutions employed advanced testing strategies, including digital twin simulations. SCADA screens, and PLC programs were built and tested in a controlled environment before deployment. Factory Acceptance Tests (FATs) allowed operators to interact with the system in real-world scenarios, identifying potential issues before they impacted live operations. During critical cutovers, temporary systems were deployed to maintain uninterrupted water service while new panels and PLCs were installed.
The result was a standardised, resilient and future-ready water system. Now in its final phase, the five-year project has transformed the region of Waterloo’s operations. By standardising automation solutions across all facilities, operators can now diagnose and resolve issues more quickly, leading to reduced downtime and increased system resilience. Enhanced monitoring capabilities provide better insights into water usage, system pressures, and response times to main breaks and emergencies.
Additionally, improved network security safeguards critical infrastructure from potential cyber threats. Brock Solutions played a key role in bridging the IT/OT gap, helping to develop an OT cybersecurity framework tailored to the region of Waterloo’s needs.
Beyond the technical improvements, the project’s success is rooted in strong collaboration and trust. “If I could emphasise one thing, it’s how much work went into building the relationship between Brock Solutions and the region of Waterloo and getting buy-in from every person,” says Andrew Calder, senior project engineer for the region of Waterloo.
By fostering a culture of open communication and continuous learning, both Brock Solutions and the region of Waterloo conveyed that modernisation was not just about upgrading technology, but also about empowering people. Thoughtful change management, extensive training and a shared commitment to problem solving have positioned the region for long-term success.
With the last major facility now nearing completion, the region of Waterloo has achieved a modernised, future-ready water management system that will serve its customers reliably for decades to come.
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