GitOps Orchestration for DCS Configuration Rollback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of safely and efficiently managing continuous configuration changes in distributed control systems (DCS) without overburdening users with multiple tools and ensuring quick recovery from failed changes is unresolved.
Innovation Solution
A method and system utilizing GitOps orchestration, which includes a versioning repository to track configuration history, perform security checks, and enable quick rollback to previous configurations, ensuring safe and flexible adaptation of DCS configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If configuration changes are applied to DCS to meet new requirements or replace hardware, then the system adaptability improves, but the risk of system failure and complexity of recovery increases
Solution Approach 1:
The system performs preliminary actions by creating snapshots of the configuration state before applying changes, and by validating changes against a model before deployment. This allows the system to prepare recovery mechanisms in advance, reducing the risk associated with configuration changes while maintaining adaptability.
Solution Approach 2:
The system implements beforehand cushioning through automated rollback mechanisms and configuration validation. If changes cause system failure, the pre-prepared snapshots and automated rollback processes act as a cushion to protect the system, automatically restoring the previous stable state without requiring manual intervention.
2Reliability
If manual reversal of configuration changes is performed to restore system functionality, then system reliability is maintained, but the recovery time and operational complexity increase
Solution Approach 1:
The system implements self-service through automated rollback mechanisms that automatically detect configuration failures and restore previous working states without human intervention. The system monitors configuration changes, detects failures, and autonomously executes recovery procedures, eliminating the need for manual reversal operations.
Solution Approach 2:
The system uses feedback mechanisms to continuously monitor the health and functionality of the DCS after configuration changes. When failures are detected, the feedback loop triggers automated rollback procedures, enabling rapid recovery based on real-time system state information rather than manual assessment.
3Ease of operation
If multiple configuration tools are provided to manage different aspects of DCS, then the ease of operation for specific tasks improves, but the overall system complexity and user burden increase
Solution Approach 1:
The system merges multiple configuration management functions into a single integrated GitOps orchestration platform. Configuration changes, validation, deployment, monitoring, and rollback operations are unified in one system that uses Git as its core mechanism, eliminating the need for users to switch between multiple specialized tools while maintaining comprehensive functionality.
Solution Approach 2:
The GitOps orchestration system implements universality by providing a single platform that handles diverse configuration management tasks including hardware configuration, software updates, security patching, and system recovery. This multi-functional approach replaces multiple specialized tools with one universal system that adapts to different configuration needs through a common Git-based interface.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
There is disclosed a method for changing a configuration of a distributed control system, DCS, associated with a production process in industrial plant, the method comprising: obtaining, at a system orchestrator associated with the DCS, wherein the DCS has a first configuration, first data indicative of a second configuration to be applied at the DCS; applying changes on the first configuration based on the second configuration as a first target configuration; determining, based on predetermined determination criteria, whether to reverse at least part of the applied changes; based on a result of the determining, obtaining second data indicative of a historic configuration of the DCS from a versioning repository in which data indicative of historic configurations of the DCS comprising at least the first configuration are stored; and reversing at least part of the applied changes based on using at least part of the obtained historic configuration as a second target configuration.