Beyond the Threshold

At Uxeed Inc, we love solving complex challenges. But our favorite challenges are the ones that don’t require ripping and replacing an entire system. Often, the true value is unlocked by building intelligent layers on top of the infrastructure you already have.

A recent project with a client in the Oil & Gas sector is a perfect example.

The Challenge: “Alarm Fatigue” from a Rudimentary System

Our client relies on a robust SCADA (Supervisory Control and Data Acquisition) system to monitor their field operations. While the system was great for data collection, its alarm features were extremely basic.

The system could only trigger an alarm based on a simple threshold for a single data point (e.g., “Pressure > X”).

This created a massive problem: “alarm fatigue.” Operators were constantly flooded with notifications, most of which weren’t critical. A temporary pressure spike might trigger an alarm, but it wasn’t a real issue. A “low flow” alarm could be an annoyance, or it could be a sign of a critical failure.

Because operators were drowning in this “noise,” they couldn’t distinguish high-priority alerts from low-priority ones. This led to slower response times, missed critical events, and wasted manpower.

The Solution: A Custom Web App for Complex, Multi-Point Alarms

We designed and integrated a new, custom web application that sat on top of their existing SCADA system. The core of this solution was a powerful, yet intuitive, alarm configuration interface.

This new UI allows operators to move beyond single-point thresholds and create sophisticated, multi-point alarms using complex boolean logic (AND/OR groups).

Instead of just alarming on one “bad” number, operators can now build rules that reflect true operational problems.

What does a “Smart Alarm” look like?

Here are a few real-world examples of complex alarms this new system enables:

• Predictive Pump Failure:

  • IF (Differential Pressure > X) AND (Flow Rate < Y)
  • This combination doesn’t just say “flow is low.” It says “the pump is working hard (high dP), but nothing is moving (low flow).” This is a clear indicator of a critical blockage or imminent pump failure, allowing for proactive maintenance.

• Pipeline Leak Detection:

  • IF (Static Pressure < A) AND (Flow Rate > B)
  • Either of these conditions alone might be normal. But together, a sudden drop in pressure combined with an unexpected high flow rate is a classic sign of a potential line break.

• Well Integrity Warning:

  • IF (Casing Pressure > P1) AND (Casing Pressure > Static Pressure * 1.5)
  • This alarm is dynamic. It checks not only for a high casing pressure but also compares it relationally to the static pressure, providing a much more reliable indicator of a potential well integrity issue.

This new approach fundamentally changed the nature of their alarms—shifting them from “noise” to “actionable insight.”

The Results: Faster Reactions, Lower Costs, and Higher Production

By filtering out the noise and delivering high-importance notifications, the benefits were immediate and compounded over time.

• Drastically Reduced “Alarm Fatigue”: Operators now receive far fewer notifications, but when an alarm does trigger, they know it’s important and requires immediate attention.
• Faster, More Proactive Responses: With clear and contextual alarms, operators can react before a small issue cascades into a costly crisis. This significantly reduces time spent on-site reacting to emergencies.
• Decreased Downtime & Maintenance Costs: Proactive maintenance is always cheaper than reactive repairs. Catching a pump failure before it happens means less downtime, lower repair bills, and optimized maintenance schedules.
• Increased Production: Less downtime directly translates to more uptime and higher production output.
• Improved Diagnostics: The alarm itself now contains valuable context. The team doesn’t just know “Pressure is high”; they know “Pressure is high while flow is zero,” which points them directly to the likely cause.

Taking It One Step Further: From Insight to Action

An alarm is only useful if it leads to action. To close the loop, we integrated the new smart alarm system directly with the client’s existing task management and dispatch platform.

Now, when a critical smart alarm triggers, the system doesn’t just send an alert. It automatically:

1. Creates a dispatch task in their system.
2. Populates the task with all the relevant alarm details (what triggered, when, and potential causes).
3. Assigns the task to the correct on-call operator based on their route and shift.

This final step transformed the operator’s workflow. They moved from a reactive, chaotic scramble to a structured, centralized queue of actionable work.

You Don’t Always Need to Start from Scratch

This project is a perfect example of our philosophy: You don’t always need to replace your core systems. The true value often lies in enhancing and extending what you already have. We build the custom layers that connect your existing infrastructure to modern, intelligent solutions.

Is your team struggling with an inflexible legacy system? Are your operators buried in “alarm noise”? Let’s talk. We can help you build the tools to unlock the true power of the data you already have.