Virtual SCADA Controller Failover for Utility Automation
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Solution Overview
Problem
Automation controllers in utility systems, such as RTACs, are vulnerable to faults which disrupt communication and require physical replacement, leading to delays and potential forensic data destruction, with existing failover solutions being costly and requiring manual intervention.
Innovation Solution
A virtual SCADA controller system that detects faults and takes over control of intelligent electronic devices via a programmable network routing device, allowing uninterrupted operation and remote management, enabling hot or cold swapping of physical controllers without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical SCADA devices are added for failover, then system reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a virtual copy (virtual SCADA controller) of the physical SCADA controller that can take over operations when the physical controller fails. This virtual copy replicates the control functionality and state information, enabling failover without requiring additional physical hardware at the remote location, thus improving reliability while avoiding the complexity and cost of deploying multiple physical devices.
Solution Approach 2:
The patent transitions from a purely physical hardware-based failover solution to a virtualized software-based solution that operates in a different dimension (virtual computing environment). By deploying the virtual SCADA controller on remote computing infrastructure rather than requiring additional physical SCADA hardware, the system achieves failover capability without increasing device complexity.
2Reliability
If physical controller replacement is performed, then fault recovery is achieved, but system downtime increases
Solution Approach 1:
The virtual SCADA controller is pre-configured with the necessary control logic and can immediately assume control operations when a physical controller failure is detected. This preliminary setup eliminates the need for time-consuming physical replacement operations, as the virtual controller is already in place and ready to take over, thereby reducing system downtime while achieving fault recovery.
Solution Approach 2:
The virtual SCADA controller acts as an intermediary between the failed physical controller and the rest of the system. It maintains communication with intelligent electronic devices and control centers, allowing the system to continue operations during the transition period while the physical controller is being replaced or repaired, thus minimizing downtime.
3Loss of information
If physical controller is left in place for repair, then forensic data is preserved, but risk of fault reoccurrence increases
Solution Approach 1:
The virtual SCADA controller creates a functional copy that can operate independently of the physical controller's operational state. This allows the physical controller to remain in place for forensic analysis while the virtual controller handles control operations, effectively separating the forensic preservation function from the operational function and eliminating the risk of fault reoccurrence affecting the operational system.
Solution Approach 2:
The patent segments the control system into two independent parts: the physical controller (kept for forensic analysis) and the virtual controller (used for operations). This segmentation allows the physical controller to remain undisturbed for investigation while the virtual controller continues to manage control operations, thus preserving forensic data while eliminating the risk of the same fault recurring in the operational system.
4Ease of operation
If manual intervention is required for failover, then control over the process is maintained, but productivity decreases
Solution Approach 1:
The system implements automatic failover detection and execution through the virtual SCADA controller, which monitors the physical controller's health and autonomously takes over control operations when a failure is detected. This self-service capability eliminates the need for manual intervention in the failover process, thereby improving productivity while maintaining operational control through the virtualized environment that can be remotely managed.
Data Source
AI summary
One or more virtual supervisory control and data acquisition (SCADA) controllers are provided. The virtual SCADA controller(s) may be deployed upon a detection of a failure of a physical SCADA controller. An on-site module may detect failure including a security breach which causes the physical SCADA controller to be disconnected from a network and the virtual SCADA controller(s) to take over control. The virtual SCADA controller(s) may be on-site or off-site.