Monitoring 300+ Remote Stations
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.
EdgeConnect - Unified Namespace Originator
Deployment Pattern
EdgeConnect at each station (300+ sites) on CISCO routers
Key Design Decisions
EdgeConnect deployed in Cisco IR1101 routers (reduced hardware footprint)
Store-and-forward for satellite communication resilience
UNS architecture with Sparkplug B for auto-discovery
Architecture Components
Component | Specification | Quantity |
|---|---|---|
Edge Nodes | EdgeConnect in Cisco routers | 300+ |
Protocols | Modbus RTU, DNP3, HART | Multiple |
Data Points | 50-200 per site | 500,000 total |
Update Rate | 10 seconds | Optimized |
Redundancy | Store-and-forward, dual path | All sites |
Edge Intelligence Configuration
At Each Station (EdgeConnect)
Direct PLC/RTU communication (Modbus, DNP3)
MQTT Sparkplug B publication to regional/central
UNS Architecture
Field Level: Sensors → PLCs/RTUs → EdgeConnect
Edge UNS: Local namespace definition, context added
Network: Process and manage data in the broker
Measured Outcomes
Operational Improvements
75-80% reduction in operational costs
Zero middleware licensing fees
100% uptime during satellite outages (store-and-forward)
60% reduction in alarm flooding
Technical Achievements
Sub-second local response times
Automatic configuration deployment to new sites
Native integration with existing SCADA without replacement
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
1. The Problem
Challenge: Operate and observe hundreds of distributed midstream sites with PLCs and intermittent, bandwidth-limited links—while keeping on-site autonomy and ensuring a unified, secure, and scalable publish/subscribe model for corporate operations, analytics, and alarms.
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2.2 Logical Diagram (high level)
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| Scada & Enterprise Applications |
| ↑↓ |
| Redundant Brokers |
| ↑↓ |
| EdgeConnect Product Edition |
| ↑↓ |
| PLCs on field: DF1, ControlLogix, etc... |
2.3 Topology
Layer | Component | Role | Notes |
|---|---|---|---|
Field | ControlLogix (CIP), DF1 devices | Signals/controls | - |
Edge (Site) | EdgeConnect (Linux) | Collection, buffer, publish | Runs on router/IPC; AutoStart; Watchdog; local logging |
Transport | Satellite / WAN | Telemetry backhaul | - |
Brokers | MQTT brokers (HA, N=4) | Pub/Sub backbone | Persistent sessions, retained health topics |
Consumers | SCADA/Historian/Analytics | Enterprise visibility & actions | - |
...