Secure Connectivity for Gas Distribution Stations

Background

In the gas distribution industry, continuous real-time monitoring and control of infrastructure is essential for both safety and regulatory compliance. This includes gas pressure regulation stations and gas transfer nodes, which must remain online even in the event of equipment failure or communication disruptions.

A major gas utility company required a high-availability solution for its field stations across the country. Their primary challenge: how to ensure uninterrupted communication with PLCs and dataloggers at each site — even in the event of hardware failure — while adhering to strict security standards and working over legacy industrial protocols like Modbus RTU.

System Requirements

The key requirements were:

• Redundant architecture at every gas transfer station: full operation must continue even if a router fails.
• Support for both Modbus RTU and Modbus TCP.
• Multiple RS485 and RS232 industrial interfaces for dataloggers and PLCs.
• Full cross-linked communication topology between routers and field devices.
• Routers are Cybersecurity compliant with IEC 62443.
• Centralized device management, diagnostics, and deployment through WebAccess/DMP.

In addition, the system needed to be robust enough for harsh environments and easy to scale as the gas network expands.

System Description

Each gas transfer station was equipped with two Advantech ICR-2834 industrial LTE routers. These routers offer:

• Dual RS485 and RS232 ports, allowing direct communication with PLCs and dataloggers.
• Modbus RTU/TCP protocols conversion, enabled by an embedded Router App.
• Hardware-ready features for redundant installations, including dual SIMs.

The routers were deployed in a fully redundant, cross-linked topology:

• Each router is connected to all local PLCs and dataloggers using RS485 bus.
• If one router or link fails, the second takes over seamlessly.
• All field devices remain accessible via at least one communication path.

This architecture guarantees failover protection without needing additional switches or control units.

Entire network is managed through On-Premise WebAccess/DMP operating in safe company environment.

Project Implementation

The implementation was executed in phases:

1. Hardware installation: Each station was outfitted with two ICR-2834 routers, with cross-wired RS485 lines to ensure every PLC and datalogger had redundant communication paths.
2. Router App deployment: Each device was configured to support Modbus RTU to TCP translation, allowing seamless integration with SCADA systems.
3. WebAccess/DMP onboarding: All routers were registered and provisioned through the cloud-based management system, enabling centralized control.
4. Security compliance: System design and deployment followed the principles of IEC 62443, including device hardening, encrypted data channels, and access control policies.

This design ensures that if one router fails or loses connectivity, the second router maintains full communication with all connected devices — delivering true high availability at the field level.

System Diagram

Conclusion

By implementing a redundant and secure communications infrastructure using Advantech ICR-2834 routers and WebAccess/DMP, the gas utility company achieved:

• 99.98% operational continuity at gas transfer stations.
• Routers in compliance with industrial cybersecurity standards (IEC 62443).
• Seamless support for both serial and Ethernet-based Modbus protocols.
• A scalable architecture that simplifies rollout to new locations.

The project highlights how industrial IoT technology can modernize traditional infrastructure with zero compromise on safety, security, or uptime — critical factors for the energy sector.