Overview

Understanding Advanced Flow Management

Advanced flow management represents the third generation of flow monitoring capabilities in WeatherTRAK systems. The evolution began with basic flow management in the Pro 2 controllers, which could monitor flow on systems with one point of connection and one controller. The Pro 3 upgrade introduced the ability to listen to multiple flow sensors and handle more complex hydraulic conditions like looped mainlines and multiple source systems.

OptiFlow takes flow management to the next level by enabling flow monitoring across as many as 30 controllers at once and up to 40 points of connection. This capability opens up flow monitoring to virtually any irrigation system running WeatherTRAK, regardless of configuration complexity. The system can now track gallons and manage flow across multiple controllers and connection points, protecting against mainline breaks and station breaks while providing detailed water usage data for any given night.

System Configuration Requirements

To implement advanced flow management, the fundamental requirement is straightforward: you need a flow sensor on every point of connection, with each sensor running back to a controller. Once this infrastructure is in place, the system can begin tracking gallons and managing flow across the entire site.

Advanced system configurations typically include multiple points of connection or controllers, looped mainlines, or shared mainline configurations. When you add flow monitoring to these complex setups, you'll install a master valve and flow sensor at each connection point. The master valve must be open for irrigation to occur, which creates coordination challenges in manual operation but becomes seamless with OptiFlow's automated management.

Managing Manual Irrigation Across Multiple Controllers

Manual irrigation presents significant logistical challenges when managing multiple controllers across an irrigation system. When you add a master valve to a point of connection, that master valve must be open for any irrigation to happen downstream.

For example, if you want to operate a station valve on Controller B, the system needs to turn on the master valve on Controller A and the station valve on Controller B simultaneously to deliver water to the desired heads. Coordinating this manually across multiple controllers is nearly impossible.

OptiFlow solves this challenge through programming. Once configured, the system automatically knows all the components that need to activate to deliver water where you want it. When you prompt manual irrigation in the field, OptiFlow seamlessly activates all necessary master valves and station valves across multiple controllers, making a previously impossible task simple and transparent to field operators.

Automated Schedule Optimization Process

OptiFlow orchestrates multiple controllers to work together and deliver an optimized irrigation schedule across the entire site. The optimization process follows a specific sequence each night:

1. Each controller continues to monitor WeatherTRAK information independently, tracking each station's depletion level.

2. Each controller identifies which stations need to irrigate that night and which ones don't based on their individual depletion status.

3. All station data is delivered up into the cloud where OptiFlow creates a site-based irrigation schedule.

4. OptiFlow takes all station values and overlays them onto all the constraints of the piping infrastructure to create an optimized schedule for the entire site.

5. The system downloads specific instructions to each controller individually.

The downloaded instructions differ significantly from classic WeatherTRAK or traditional irrigation scheduling. Instead of just a run order, each controller receives very specific instructions that allow it to run as many as eight stations at once. The system specifies the exact minute and second each station should begin and end to optimize irrigation across all controllers and components while staying within restricted schedule windows.

AT&T Stadium Case Study: System Overview

The Dallas Cowboys' AT&T Stadium provides an excellent example of advanced flow management in a complex, high-profile environment. The site operates 17 WeatherTRAK controllers total, with seven controllers running OptiFlow on the main loop around what they refer to as the "postage stamp"—the building and surrounding parking lots.

The main loop varies from three to four inches in diameter and serves approximately 11 acres of irrigated landscape. The system faces unique challenges due to the high-traffic nature of the venue, frequent events, and the need for extremely short water windows. Some outer lots are located almost a mile away from the central building, requiring reliable communication across the entire property.

Cellular Communication Advantages

One of the major driving factors in selecting WeatherTRAK for AT&T Stadium was the cellular communication capability of the controllers. While the facility has WiFi available, it's inconsistent in some of the outer lots. The cellular-driven communication system ensures that all controllers communicate together reliably and can be controlled from a central point, regardless of their location on the property.

This centralized control capability is essential for managing irrigation across such a large, distributed site where some areas are nearly a mile away from the main building.

Looped Mainline Challenges and Solutions

The looped mainline configuration at AT&T Stadium presented significant operational challenges before OptiFlow implementation. The system was constructed without adequate isolation valves or master valves at key points. When a mainline break occurred or valve maintenance was required, draining the mainline took upwards of eight hours.

This extended downtime was unacceptable given the back-to-back event schedule at the venue. Flow monitoring became critical for several reasons:

Catastrophic break detection: The system pumps upwards of 600 gallons per minute. When breaks occur, water can flood public spaces, roads, and high-traffic areas. One incident at 12:30 AM at the end of a concert flooded a public road, demonstrating the disaster potential of undetected breaks.

Faster problem identification: OptiFlow provides detailed information that helps pinpoint problem locations quickly, significantly shortening the drain process and repair time.

Reduced system downtime: With better information about where problems are occurring, the maintenance team can respond more quickly and get the system back online faster.

Elevation Challenges and Flow Sensor Calibration

Despite being located in flat Texas terrain, AT&T Stadium has significant elevation changes that impact flow management. The field level sits approximately 60 feet underground, while the highest points of the property are considerably higher, creating an overall elevation change of 30 to 40 feet from the high end to the low end of the property.

These elevation differences created challenges in managing the six points of connection and their perceived failures. When optimization occurs on the northeast portion of the property (which is lower), the point of connection on the southwest corner (the highest point) compensates to maintain flow. This dynamic caused false alarms initially.

The solution required ongoing tweaking over approximately a year to year and a half to establish what constitutes a true break versus normal system operation. The ability to see what the system was doing in real time—viewing actual meter readings and master valve operation—provided the information needed to adjust settings and create more accurate outputs that reflect what's realistically happening.

Collaborative Problem-Solving Process

Implementing OptiFlow at AT&T Stadium required close collaboration between the stadium team and HydroPoint. When initial installation revealed situations where the software didn't perform as needed, HydroPoint built a demo version of AT&T Stadium's controller configuration in their corporate office. This allowed them to test solutions before rolling them out to the live site.

The partnership worked within challenging constraints, including a narrow window for system modifications (March 1st through August 1st) due to the busy event schedule during other times of the year. The solutions developed through this collaboration resulted in features now called "multi-manager," which have been rolled out to other OptiFlow sites, benefiting the broader customer base.

Water Pressure and Source Configuration

AT&T Stadium benefits from excellent water pressure supplied by the City of Arlington. The city mains provide sufficient pressure that no pump is required, even with the significant elevation changes on the property. Some areas receive almost 70 PSI at the head even when 10 to 12 zones are running simultaneously.

While the property does have infrastructure dedicated to building water supply, cooling towers, and pump stations, the irrigation system doesn't tap into these resources due to the adequate pressure from the city supply.

Master Valve Selection: Normally Open vs. Normally Closed

The choice between normally open and normally closed master valves at AT&T Stadium was driven by a specific operational need. Initially, the system used normally closed master valves with the HydroPoint-provided flow meters.

However, when a property-wide festival called KAABOO requested use of portions of the irrigation system for comfort stations (portable bathrooms), the normally closed master valves didn't play well with this temporary use. The system would lock down when these portable facilities were connected.

To accommodate this type of situation, the team replumbed the system and changed to normally open master valves. While most properties won't face this specific situation, it demonstrates the importance of considering all potential uses of the irrigation infrastructure when selecting valve types.

Hydraulic Tree Programming

The hydraulic tree setup for AT&T Stadium is relatively straightforward despite the system's complexity. The configuration consists of one looped mainline with all stations assigned to that mainline. There wasn't a need for extensive detail in breaking out sub-mains and sub-sections.

The system manages the entire mainline to 600 gallons per minute capacity all at once. This approach has proven successful for the site's needs. The configuration shows six different points of connection from five different controllers, with seven controllers total sharing information across the system.

Optimization Settings and Capacity Management

The AT&T Stadium system is configured with a 650 gallon per minute capacity but optimizes to 600 gallons per minute. This means the system can use as much as 650 GPM if needed, but targets 600 GPM during optimization to maintain a safety margin.

When viewing any five-minute window in the optimization schedule, you can see as many as seven different controllers pulling irrigation from the main line simultaneously. The display shows which specific controllers and stations are activated to keep the mainline running at its target capacity.

The optimization page allows you to view individual programs and see exactly how the irrigation system will perform on any given night. You can check which programs will run when, and if the schedule doesn't meet your needs, you can make changes from the dynamic programming environment.

Making Real-Time Schedule Adjustments

The OptiFlow interface allows for flexible schedule management without disrupting the overall optimization. You can change water windows, adjust start times, and then reoptimize to see if your changes achieve the desired effect before saving them.

At AT&T Stadium, the optimization is generally kept at a stable baseline, but adjustments are made regularly based on operational needs. For example, when projects are ongoing outside, programs are pulled on and off, moved out of auto mode, or adjusted in user-defined ET settings. The system allows management of individual controllers almost as if they're standalone units, while still maintaining the benefits of coordinated optimization across all controllers.

Using Optimization Data for Troubleshooting

The optimization page serves as a powerful troubleshooting tool beyond just scheduling irrigation. When an alert comes in—for example, indicating a potential mainline break—the maintenance team can use the optimization display to quickly diagnose the problem:

1. Review the overall optimization window to identify when the alert occurred.

2. Click on the bars in the timeline corresponding to the alert time to see which zones were running.

3. Dispatch crew members to each of the individual controllers that were active during the alert.

4. Have crew members run those specific zones independently to check for large lateral breaks.

This systematic approach dramatically shortens the window for identifying and repairing problems. Instead of spending hours searching for issues across 11 acres, the team can pinpoint problem areas and often complete repairs the same day or the day after detection. This represents a significant improvement over previous repair timelines.

Distinguishing False Alarms from Real Problems

Experience with the system helps distinguish false alarms from genuine problems. Day-to-day knowledge of the system's capabilities and the mainline's characteristics is valuable—at AT&T Stadium, real problems with the mainline are typically catastrophic failures due to the volume and pressure involved, making them obvious.

When analyzing alerts, it's important to understand the difference between actual flow and measured flow. The numbers WeatherTRAK delivers are exactly what it measured, so use that data as a guidepost. In a high flow alert situation, start with the measured data and then drill down to figure out where the issue occurred. All the data needed for analysis is available at your fingertips in the system.

Station-Level Flow Adjustments and Relearning

OptiFlow allows for both station-level and program-level adjustments. When the initial learn function is performed, the system captures flow quantities for each station based on the existing configuration.

If you need to make changes later—for example, switching to a larger nozzle that changes the precipitation rate—you have the capability to modify those settings. After making physical changes to the system, you can hit the relearn button to have the system measure and record the new flow amount for that zone based on the increased nozzle size or other modifications.

This flexibility allows the system to stay accurate as your irrigation system evolves over time, ensuring that optimization continues to work with current, real-world flow rates rather than outdated baseline data.

Dramatic Water Window Reduction

One of the most significant benefits of OptiFlow at AT&T Stadium has been the dramatic reduction in required water windows. Previously, the system required a 10-hour water window to irrigate roughly 11 acres. With OptiFlow optimization, that window has been reduced to as little as four hours and 40 minutes.

For facilities working with common areas, high-traffic spaces, and frequent events, this reduction is a game changer. Shorter water windows mean irrigation doesn't affect ingress or egress, doesn't impact public safety, and doesn't interfere with event setup or operations. The ability to get in and get out with water needs met in less than half the previous time provides tremendous operational flexibility.

Performance Standards and Efficiency Gains

At a high-profile venue like AT&T Stadium, the primary goal isn't water savings—it's delivering a high level of performance and appearance that meets ownership expectations for events like Monday Night Football and other televised occasions. The ability to deliver that high level of performance with high efficiency is what OptiFlow provides.

The system enables the flexibility to make significant schedule changes quickly to please network TV crews and various stakeholder groups that have input into what the facility looks like. Despite performance being the priority over conservation, the actual water usage data shows impressive results: the facility is saving almost 20% compared to usage from five years ago.

This demonstrates that optimization for operational efficiency and performance can deliver substantial water savings as a secondary benefit, even when conservation isn't the primary objective.

Video Walkthrough

Video originally published April 2021.

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