DCS Network Migration via Redundant Component Switchover
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Solution Overview
Problem
Conventional Distributed Control Systems (DCS) face difficulties in migrating from legacy technology to modern technology due to the continuous processing nature of these systems, making network migration challenging and often prohibitive.
Innovation Solution
A method and system for process control network migration that involves disconnecting redundant components, updating hardware and software to enable communication on a new network, synchronizing data between components, and switching redundant modes to allow seamless migration while maintaining continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If network migration is performed in conventional DCS, then technology modernization is achieved, but system continuity is disrupted
Solution Approach 1:
The system divides the network migration process into discrete segments: identifying redundant components, updating hardware/software, synchronizing data, and switching modes. This segmentation allows migration to proceed in controlled steps without disrupting overall system continuity.
Solution Approach 2:
The method performs preliminary actions by updating hardware and software on redundant components before switching them to primary mode, and by synchronizing data in advance. This ensures that when the switch occurs, all necessary preparations are complete, maintaining system continuity.
2Adaptability or versatility
If redundant components are updated during operation, then migration capability is improved, but data synchronization complexity increases
Solution Approach 1:
The system uses redundant components as copies of the primary components. By updating the redundant copy first and then synchronizing it with the primary, the complexity of updating operating components is avoided. The redundant component serves as a test bed for updates before they are applied to the active system.
Solution Approach 2:
The synchronization process establishes feedback loops between redundant and primary components, allowing data to be exchanged and verified. This feedback mechanism ensures data consistency during migration while managing synchronization complexity through structured communication protocols.
3Adaptability or versatility
If redundancy mode switching is implemented, then migration flexibility is improved, but control logic complexity increases
Solution Approach 1:
The system implements dynamic redundancy mode switching, allowing components to transition between primary and redundant states based on migration progress. This dynamic approach provides migration flexibility while using standardized switching logic that reduces overall control complexity compared to static configurations.
Data Source
AI summary
A method includes disconnecting a first component from a first network. The first component is redundant to a second component and operates in a secondary or passive redundancy mode. The second component operates in a primary or active redundancy mode and is coupled to the first network. The method also includes updating at least one of hardware and software on the first component to allow the first component to communicate on a second network. The method further includes connecting the updated first component to the second network and synchronizing data between the updated first component on the second network and the second component on the first network. In addition, the method includes switching the updated first component from the secondary redundancy mode to the primary redundancy mode.