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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
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EdgeConnect at each station (300+ sites) on CISCO routersEnterprise 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
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Architecture Components
Component | Specification | Quantity | ||||
|---|---|---|---|---|---|---|
Edge Nodes | EdgeConnect in Cisco routers | 300+ | ||||
Protocols | Modbus RTU, DNP3, HART | Multiple | ||||
Data Points | 50-200 per site | 35500,000 total | ||||
Update Rate | 1 second local, 30 second to center | Optimized | Storage | 30 days local SQL | Per site10 seconds | Optimized |
Redundancy | Store-and-forward, dual path | All sites |
[Implementation Details]
Edge Intelligence Configuration
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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
Field Level: Sensors → PLCs/RTUs → EdgeConnect
Edge UNS: Local namespace definition, context added
Regional UNS: Area aggregation via DataHub Station
Enterprise UNS: Complete operational view via Enterprise Unlimited
Cloud Integration: Select KPIs to Azure for corporate dashboards
[Results Achieved]
Network: Process and manage data in the broker
Measured Outcomes
Operational Improvements
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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
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All phases use same architecture pattern with no redesign required.
[Bottom Section]
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
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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 | - |
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