Virtualized SCADA Control for Well Operations
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Solution Overview
Problem
Current SCADA systems for well operations lack sufficient redundancy and uptime, making them vulnerable to hardware failures and single points of failure, such as communication cable ruptures, which can lead to downtime and reduced security.
Innovation Solution
Implementing a virtualization process where well operation management and control systems run on identical virtual simulated environments across at least two servers, with all data stored in a designated redundant Cluster Storage System and utilizing load balancing to distribute workload, thereby reducing the risk of hardware-related failures and enabling seamless upgrades without downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical components are used for communication between servers and PLCs, then the system structure is simple, but the system is vulnerable to single points of failure such as communication cable ruptures
Solution Approach 1:
The patent creates virtual copies of PLCs and control systems that run on virtualized servers. Instead of relying on a single physical PLC, the system maintains multiple virtual instances that can take over if one fails. This virtual copying eliminates single points of failure while keeping the physical infrastructure relatively simple.
Solution Approach 2:
The patent introduces a virtualization layer as an intermediary between the physical PLCs and the control software. This virtual layer abstracts the physical hardware, allowing the system to manage complexity at the virtual level while maintaining simpler physical connections. The virtualization platform mediates communication and provides redundancy management.
2Reliability
If hardware-based PLCs are used, then the system is stable, but hardware failures lead to downtime and reduced security
Solution Approach 1:
The patent implements preemptive redundancy by maintaining standby virtual PLC instances before failures occur. When hardware failures happen, these pre-positioned virtual copies can immediately take over, cushioning the impact and preventing downtime. The system prepares backup capacity in advance rather than reacting to failures.
Solution Approach 2:
The patent creates a dynamic system where virtual PLC instances can be dynamically created, moved, or activated based on system conditions. Instead of static hardware assignments, the system can dynamically redistribute workloads to healthy servers, allowing flexible response to hardware failures and maintaining continuous operation.
3Reliability
If virtualization is implemented across multiple servers, then redundancy and security are improved, but system complexity increases
Solution Approach 1:
The patent creates a universal virtualization platform that can host multiple different PLC types and control systems on the same infrastructure. This multi-functional approach consolidates what would otherwise require separate dedicated systems, achieving redundancy without proportionally increasing complexity. The virtualization layer provides universal management across diverse components.
Data Source
AI summary
A method for improving a redundancy and an uptime in a SCADA network for controlling a well operation includes executing control systems for the well operation in identical virtual simulated environments on at least two servers, storing all data for the control systems in a designated redundant cluster storage system, and setting-up the at least two servers with a load balancing.