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Real-Time Expert Intelligent Control System REICS

After investigating the conception and features of PLC (Programmable Logic Controller) and embedded system, in this paper the conception of a Quasi-PLC is proposed, which combine the advantages of PLC and embedded system. The architecture of Quasi-PLC and a Top-Down design method with collaboration design of software and hardware for Quasi-PLC embedded control system are researched then. Finally, setting the large-scale industrial valve control system as an example, the conception of Quasi-PLC and related technologies are used in industrial valve control system, and a satisfied application effect is obtained, which proves the rationality of the conception of Quasi-PLC and related technologies.

Computer facilities and microprocessor-based technology have been successfully used in the energy industry. For protection and equipment control, this technology has been used in SCADA, remote control and monitoring applications. Particular attention is paid to the cyber security sector for automation and control systems. Protective application of the equipment and control, SCADA, monitoring and remote control, uses the technology with microprocessor. Due to the great importance of the power supply process, there is no question of being left in a state of vulnerability and neglect. Security is not perfect and will never be. For this reason, there will always be security breaches and incidents. Also, for this reason, not only protection mechanisms are in place, but also mechanisms for rapid detection of incidents and which are able to react effectively to the isolation of problems and to ensuring security. Processes security for systems will continue to evolve in the future. By definition, there are no communication systems that are 100% safe. Attacks against critical industrial infrastructures marked an increase not only in terms of number but also of the level of complexity. The destruction of the industrial control system (ICS) and critical processes were interrupted. For many organizations, the security improvement in ICS systems is great. The extreme sensitivity to ensure the availability and performance of industrial processes has led to a more conservative and rigorous approach to how security measures are implemented. Cyber-attacks that could compromise the availability, integrity, and confidentiality of ICS systems may come from within systems or from outside ICS systems. Among the ICS system infection vectors from the perspective of the SANS Institute (2014) include: external threats (state attacks, hacking etc.), malware, exploiting tools, phishing, internal attacks, cyber security protocols, and industrial espionage. This chapter addresses the cyber security issues required for the protection, automation, control and communications systems of transformation stations as well as methods that could be used to prevent computer attacks that can have a significant impact on the availability of the system Electro-energetic effect with serious consequences on extended area interruptions.

The implementation of automated regulatory control has been around since the middle of the last century through analog means. It has allowed engineers to operate the plant more consistently by focusing on overall operations and settings instead of individual monitoring of local instruments (inside and outside of a control room). A similar approach is proposed for cyber security, where current border-protection designs have been inherited from information technology developments that lack consideration of the high-reliability, high consequence nature of industrial control systems. Instead of an independent development, however, an integrated approach is taken to develop a holistic understanding of performance. This performance takes shape inside a multiagent design, which provides a notional context to model highly decentralized and complex industrial process control systems, the nervous system of critical infrastructure. The resulting strategy will provide a framework for researching solutions to security and unrecognized interdependency concerns with industrial control systems.

Control systems are used in a number of different industrial sectors and critical infrastructures, including manufacturing, distribution, and transportation. Failure of these control systems because of malware or other faults would be catastrophic for critical infrastructure and would result in significant losses. Adverse operating conditions, such as those found in networked control systems, exacerbate the likelihood of vulnerability to malware attacks. The prospect of severe adversarial assaults such as buffer overflow, conventional faults, and especially stealthy Ladder Logic Bombs is a serious cause of concern in Industrial Control Systems (ICS) with novel attacks such as Struxnet. Decoupled at-distance Electromagnetic spectrum-based monitoring of faults and malware is more robust and can likely be integrated into Industrial Control System frameworks. Our failure analysis and Machine Learning (ML) modeling approach is fundamentally different from traditional methods in that we propose a Hybrid Quantum Artificial Intelligence-based Electromagnetic (EM) Spectral domain-based analysis approach that is completely decoupled from the controller processor and can predict PLC fault/malware conditions, including stealth Ladder Logic Bombs and buffer overflow attacks. Further, robust Supervisory Control Systems (SCSs) that interface with programmable logic controllers (PLCs) are essential components of Industrial Control Systems (ICSs) that handle critical infrastructure. Modern industrial control systems, on the other hand, are made up of densely linked Internet of Things (IoT) nodes. Because of their networked nature, supervisory control systems are also susceptible to widespread cyberattacks. As a result, in the case of a coordinated attack on IoT control systems, the dependability of Supervisory control decision-making procedures is jeopardized and need to be decoupled from the attacks. This work also develops a Fuzzy inference Engine-based supervisory monitoring technology based on the characteristics of the Hybrid Quantum AI-based analysis of the EM spectrum to reduce industrial plant downtime and false alarms by localizing adversarial attacks/faults, risk severity levels, and impacted nodes, as well as having dependability and malware immunity in networked Industrial control systems. The Hybrid QAI technique improved prediction accuracy by up to 88 percent when identifying different control system viruses and defects in 6-stage pipelined processors. The Fuzzy inference engine in the Mamdani Inference System architecture has been found to reduce the risk of false alarms and downtime.

Industry 4.0 is the German vision for the future of manufacturing, where smart factories use information and communication technologies to digitise their processes to achieve improved quality, lower costs, and increased efficiency. It is likely to bring a massive change to the way control systems function today. Future distributed control systems are expected to have an increased connectivity to the Internet, in order to capitalize on new offers and research findings related to digitalization, such as cloud, big data, and machine learning. A key technology in the realization of distributed control systems is middleware, which is usually described as a reusable software layer between operating system and distributed applications. Various middleware technologies have been proposed to facilitate communication in industrial control systems and hide the heterogeneity amongst the subsystems, such as OPC UA, DDS, and RT-CORBA. These technologies can significantly simplify the system design and integration of devices despite their heterogeneity. However, each of these technologies has its own characteristics that may work better for particular applications. Selection of the best middleware for a specific application is a critical issue for system designers. In this paper, we conduct a survey on available standard middleware technologies, including OPC UA, DDS, and RT-CORBA, and show new trends for different industrial domains.

This paper addresses the pressing challenges of building secure and resilient Industrial Control Systems (ICS) by focusing on rapid attack detection, recovery, and maintaining monotonicity in online monitoring systems. Traditional methods often fail to quickly identify threats, leaving systems vulnerable to prolonged downtime. Specifically, classical online monitoring systems struggle to preserve monotonicity, as they typically detect only isolated anomalies during operation, which can mask subsequent deviations in system behavior. This research presents an advanced approach to resilient cyber-physical systems (CPS) that utilizes Signal Temporal Logic with Global Time (STL-GT) in combination with an Autotuning mechanism for robust realtime monitoring, multi-point anomaly detection, and recovery. This innovative framework enables prompt detection of attacks and faults, along with rapid system recovery. Our STL-GT online monitoring system incorporates a syntactic separation technique based on a partition rule to address monotonicity issues and improve the system's ability to detect and respond to multiple anomalies during system execution. The autotuning mechanism, based on Internal Model Control (IMC) PID tuning rules, enables swift and adaptive system recovery in the event of disruptions. We validated our methodology using the Tennessee Eastman Plant model, a complex chemical plant simulator designed to study industrial processes and control systems. Experimental results demonstrate that our approach provides effective security and resilience of the CPS by consistently detecting anomalies and restoring the system with zero overshoot and minimal oscillations, eliminating violation masking and missed alarms. These findings highlight the effectiveness of our approach in fortifying critical systems against adversarial attacks and operational faults.

Cyber-physical systems are realized as those systems where the computation, communication and physical processes interact with each other (e.g., robotic systems, automotives, etc). A large class of cyber-physical systems are associated with strict timeliness requirements. They are known as ‘real-time systems’ (e.g., smart grids, avionics, etc). Industrial control systems (ICS) are real-time systems that consist of several closed-loop controls. The main components of a control loop are — a physical plant, sensors, actuators and a controller. The sensors transmit the measurement data to the controller that generates appropriate control signals to actuate the physical plant. Large-scale wireless sensor actuator networks form the main communication framework among the network devices in ICS. Most of the communications between each of these devices are periodic real-time flows with hard deadlines. To ensure reliability, the communication in these systems are time-division multiple access (TDMA) based. Dedicated network resources (time-slots and frequencies) are allocated to these devices in advance and the communication schedule is pre-computed to satisfy the hard deadlines of the real-time flows. The same schedule is repeated over time which makes the schedule predictable in nature. However, a malicious attacker can exploit this predictable time-slots in the schedules to launch timing attacks. Since these applications are time-critical, timing attacks can completely undermine the system performance leading the system to an unsafe state. Schedule randomization is a popular defense mechanism to mitigate timing attacks. Although a few works exist in the literature that use schedule randomization as a countermeasure against timing attacks in real-time uniprocessor systems, none of them are applicable for real-time wireless networks. Schedule randomization as a countermeasure against timing attacks in real-time wireless networks remained largely unexplored. With this objective in focus, this thesis addresses some schedule randomization techniques to mitigate timing attacks in real-time wireless networks. Among the existing wireless network protocols that are in use, the WirelessHART is the most suitable and widely adopted protocol in ICS. A WirelessHART protocol supports centralized architecture, TDMA based communication, multiple channels, etc. All of these characteristics of a WirelessHART network facilitate reliable and predictable communication with real-time flow guarantees in ICS. However, the predictable communication exposes the system to timing attacks, such as selective jamming attacks. Selective jamming attacks are stealthy attacks, however, it can lead the system to an unstable state and can disrupt the safety of the system. As a countermeasure against such attack in WirelessHART network, we propose a centralized schedule randomization technique that randomizes the time-slots and channels in the schedule over every hyperperiod (least common multiple of the periods of the real-time flows) without violating the hard deadlines of the real-time flows, while still satisfying the feasibility constraints of a schedule in a WirelessHART network. The centralized technique generates the schedules offline and distributes the schedules online, hence, cannot support any change in topology in the network. Further, this technique has energy overheads in distributing the schedules to all the network devices at runtime. Hence, we propose a distributed online schedule randomization technique that can generate random feasible schedules at runtime in each network device without affecting the closed-loop control stability. To increase the extent of randomization of time-slots in the schedules, this online distributed technique adopts a period adaptation strategy that can adjust the transmission periods of the real-time flows at runtime depending on the stability of the closed-loop controls. To support an ever-growing number of devices and dense connectivity, the fifth generation (5G) cellular networks is expected to serve as the main communication standard in the future wireless sensor networks. Among the different service categories supported by 5G, the ultra-reliable low-latency communication (URLLC) is mostly suitable for time-critical applications such as the ICS. The communication in 5G is organized into slots over multiple frequencies. To satisfy the hard deadlines of the URLLC flows in ICS, a part of the resources (slots and frequencies) in 5G are reserved for URLLC traffic and the same schedule is repeated over time. The repetition of the same schedule over time makes the slots in the schedules predictable. This, in turn, makes the 5G networks vulnerable to timing attacks. However, the proposed schedule randomization techniques for WirelessHART networks are not applicable for dynamic networks like 5G where the number of flows and the amount of available network resources for URLLC flows vary at runtime. Moreover, the feasibility of the real-time flows need to be guaranteed at runtime. Hence, we propose an online schedule randomization technique that randomizes the slots and the frequencies of the periodic URLLC flows while guaranteeing the feasibility of the flows at runtime.

Automatic control has become one of the standard engineering fields and is inherently part of electrical engineering. Industrial controllers in any form are only a part of the hardware necessary for the control of industrial processes in, e.g., the process industry or manufacturing. The design of an industrial control system is greatly facilitated by an auto-tuning system, if it is available as part of the controller. Since the majority of control hardware for industry is of the proportional-integral-derivative (PID) type, most of the patents relating to auto-tuning are also about this type of control, though other patented methods and systems for control are available. In this paper, a survey of patents for autotuning methods and systems for industrial control is given. The patents are grouped into methods and systems based on model-based tuning with non-parametric and parametric models, relay tuning, multiple controllers for nonlinear processes, and other approaches. More stress is put on recent patents, but a wider survey of auto-tuning patents published in the past two decades is also given in the paper. The methods being patented are becoming more sophisticated and more universal and consequently they provide better assistance to the work of control-design engineers. Keywords: Auto-tuning system, industrial controllers, process control, PID control, controller tuning

The oil and gas industry, a vital lifeline fueling the global economy, find itself at a pivotal juncture where the convergence of operational technology (OT) and information technology (IT) has ushered in unprecedented opportunities and challenges. As digital transformation sweeps across this sector, the imperative to fortify cybersecurity defenses against ever-evolving threats has become paramount. Innovative and forward-looking oil and gas organizations across the globe are adopting the Cloud in many forms because of their digital transformation initiatives. Data lakes, edge technology, machine-to-machine communication, and machine learning (ML) algorithms have been enabling this industrial digital transformation. This transformation is also driving changes to the OT landscape, and as these environments continue to evolve, OT environments are leveraging well proven IT solution patterns to improve the productivity and efficiency of production operations. Industrial customers often start their digital transformation journey by sending OT data to the cloud for analysis and analytics without sending commands back to the industrial automation and control systems (ICAS). This process is often called "open loop" operations, since there is one-way communication from edge to cloud. Customers generally find this relatively easy to secure and manage. However, more often we are witnessing requirements to optimize operations by generating an automatic or operator-initiated response in the oil and gas production operation, rig management based on insights gained from cloud analytics. This process is often referred to as "closed loop" operations with two-way communication between edge and cloud. The security and compliance practices for closed loop operations are more rigorous because closed operations manipulate OT devices remotely. Developing these practices should be rooted in a cyber risk assessment to help businesses understand and prioritize security concerns. In this paper we propose how strengths of Cloud computing can become key enabler for oil and gas organizations in helping them enhance their overall security posture and manage risks within OT environments. We have deployed solution patterns described in this paper as the foundational pillar of several Oil and Gas organization's overall OT system architecture to unlock both "open loop" and "closed loop" operations in a secure, reliable and cost-effective manner. The specific scope items we will cover in this paper focus on a custom security uplift framework having four foundational components – 1) Cloud led architecture patterns to provide next generation network segmentation strategies in OT De-militarized Zone 2) OT asset inventory and vulnerability management 3) Centralized security monitoring and incident response with help of Artificial Intelligence and most recently providing Generative AI based virtual assistant to query security event data from OT systems. For organizations to plan their industrial digital transformation safely and securely, it is recommended that a multi-layered approach to secure the Industrial Control Systems (ICS)/OT and Cloud environments be implemented as captured in ten security golden rules in the following paper [1]. In addition to this, in the paper we propose a comprehensive architecture framework that aligns with established cybersecurity framework (CSF) such as NIST. The use case studies discussed in the paper will highlight how customer have been able to remediate critical security vulnerabilities within weeks post implementation by deploying a comprehensive asset inventory discovery and vulnerability assessment. This has help reduce mean time to identify and mitigate vulnerabilities from months to days with automated testing in pre-production environments, ensure quick detection and response towards security incidents with help of advanced security monitoring and incident response playbooks, covering 100% of the OT assets through this capability and leverage advanced data analytics, machine learning to perform log mining, data cleansing, data validation, log mining and analysis through natural language processing such as conversational AI assistants powered by large language model (LLM) in the Cloud.

In order to evaluate the network security risks and implement effective defenses in industrial control system, a risk assessment method for industrial control systems based on attack graphs is proposed. Use the concept of network security elements to translate network attacks into network state migration problems and build an industrial control network attack graph model. In view of the current subjective evaluation of expert experience, the atomic attack probability assignment method and the CVSS evaluation system were introduced to evaluate the security status of the industrial control system. Finally, taking the centralized control system of the thermal power plant as the experimental background, the case analysis is performed. The experimental results show that the method can comprehensively analyze the potential safety hazards in the industrial control system and provide basis for the safety management personnel to take effective defense measures.

Industrial control systems are cyber-physical systems that supervise and control physical processes in critical infrastructures such as electric grids, water and wastewater treatment plants, oil and natural gas pipelines, transportation systems and chemical plants and refineries. Leveraging the stable and persistent control flow communications patterns in industrial control systems, this chapter proposes an innovative control system fingerprinting methodology that analyzes industrial control protocols to capture normal behavior characteristics. The methodology can be used to identify specific physical processes and control system components in industrial facilities and detect abnormal behavior. An experimental testbed that incorporates real systems for the cyber domain and simulated systems for the physical domain is used to validate the methodology. The experimental results demonstrate that the fingerprinting methodology holds promise for detecting anomalies in industrial control systems and cyber-physical systems used in the critical infrastructure.KeywordsIndustrial control systemsfingerprintinganomaly detection

Cybersecurity for industrial control systems: A survey

All studies recently published agree. Industrial Automation and Control Systems (IACS) increasingly constitutes a target for cyber-attacks aiming at disturbing Member States’ economies, at disabling our critical infrastructures or at taking advantage from our people. Such hostile acts take place in a context of geostrategic tensions, for the satisfaction of organised crime’s purposes, or else in support of possible activist causes. In this context, the ERNCIP Thematic Group (TG) “Case studies for the cybersecurity of Industrial Automation & Control Systems” was started in January 2014 to answer the question: “Do European critical infrastructure operators need to get IACS’ components or subsystems tested and “certified” (T&C) with regards to their cybersecurity?” And should the answer have been yes, it had to answer a corollary question: “What are (roughly) the conditions of feasibility for implementing successfully a European IACS components cybersecurity Compliance & Certification Scheme?” This TG’s undertaking was a research project, not a task force seeking to deliver an immediately applicable standard. It mobilised representatives of IACS vendors, industrial operators, European Istitutions and national cybersecurity authorities.

Industrial Control Systems (ICS) are used worldwide in critical infrastructures. An ICS system can be a single embedded system working stand-alone for controlling a simple process or ICS can also be a very complex Distributed Control System (DCS) connected to Supervisory Control And Data Acquisition (SCADA) system(s) in a nuclear power plant. Although ICS are widely used today, there are very little research on the forensic acquisition and analyze ICS’s artefacts. In this paper we present a case study of forensics in ICS where we describe a method of safeguarding important volatile artefacts from an embedded industrial control system and several other sources.