Page History

...

A major midstream operator needed to modernize monitoring across hundreds of remote pipeline stations while maintaining 24/7 operations. Legacy RTUs required expensive middleware, limited data collection, and provided no local intelligence.

[Architecture Overview]

EdgeConnect - Unified Namespace Originator

...

• EdgeConnect at each station (300+ sites) on CISCO routers

• Enterprise Unlimited at control center

• DataHub Stations at regional hubs (6 locations)

Key Design Decisions

• EdgeConnect deployed in Cisco IR1101 routers (reduced hardware footprint)Local SQL database for 30-day historian at each site

• Store-and-forward for satellite communication resilience

• UNS architecture with Sparkplug B for auto-discovery

[Technical Specifications]

Architecture Components

...

Edge Intelligence Configuration

...

• Direct PLC/RTU communication (Modbus, DNP3)

• Local calculations (flow totals, leak detection algorithms)

• Python scripts for anomaly detection

• MQTT Sparkplug B publication to regional/central

Regional Hubs (DataHub Station)

• Aggregation of area stations

• Regional historian (1 year retention)

• Alarm management for area

• Report generation

Control Center (Enterprise Unlimited)

• System-wide visualization

• Predictive analytics

• Regulatory reporting

• Integration with PHMSA compliance systems

[Data Flow]

UNS Architecture

1. Field Level: Sensors → PLCs/RTUs → EdgeConnect

2. Edge UNS: Local namespace definition, context added

3. Regional UNS: Area aggregation via DataHub Station

4. Enterprise UNS: Complete operational view via Enterprise Unlimited

5. Cloud Integration: Select KPIs to Azure for corporate dashboards

...

1. Network: Process and manage data in the broker

Measured Outcomes

Operational Improvements

...

• Sub-second local response times30-day edge autonomy during communication loss

• Automatic configuration deployment to new sites

• Native integration with existing SCADA without replacement

[Scalability Path]

Growth Architecture

Phase 1 (Completed): 300 pipeline stations
Phase 2 (In Progress): Add 150 compressor stations
Phase 3 (Planned): Integrate 50 storage facilities
Future: ML models for predictive maintenance

All phases use same architecture pattern with no redesign required.

...

Build This Architecture

Deployment Time for Phase 1: 8-12 weeks for 50 sites
Current Stage: 300+ sites
Required Products: EdgeConnect ($750/site), Enterprise Unlimited ($11,900), DataHub Station ($2,000 x 6)
Total Architecture Cost: ~$250,000 for complete 300-site system

...

• Edge tier (site): EdgeConnect on Linux (router) polls ControlLogix (CIP/EtherNet/IP) and DF1 devices, and publishes via MQTT/Sparkplug B.

• Backhaul: Satellite or constrained WAN with store-and-forward, rate limiting, compression, and payload batching.

• Broker tier: Redundant MQTT brokers (N=4).

• Clients/consumers: Third-Party brokers consumers.

2.2 Logical Diagram (high level)

2.3 Topology

...