In 2013, the UK Government Office for Science produced a report, entitled the Future role for energy in manufacturing. In this report, they identified two threats to UK-based manufacturers. The first was that the price of energy in the UK will rise, compared to the cost faced by competitor firms abroad, placing UK manufacturers at a significant disadvantage. Well, the price has risen but globally because of the Russia Ukraine war. Nevertheless, the threat to UK manufacturing is still valid. The second threat is that a low-carbon electricity supply will be unreliable, and that the cost of power cuts will rise. Well, that is certainly true if you rely solely on low-carbon electricity. But using multiple sources of power can be greatly beneficial.

The PSM system can be used for applications such as:

• Electrical power consumption monitoring and reporting
• Fault monitoring
• Generator control features for generator to power grid synchronization
• Demand penalty cost reduction/load shedding

The PSM system consists of:

• PSM module – A standard IC694 module that mounts in an RX3i main rack. The PSM module provides the DSP capability.
• Terminal Assembly – A panel-mounted unit that provides the interface between the PSM module and the input transformers.
• Interface cables – Provide the GRID 1 and GRID 2 connections between the PSM module and the Terminal Assembly

The image below shows how a basic PSM system can be connected.

PSM System Features

• Uses standard, user-supplied current transformers (CTs) and potential transformers (PTs) as its input devices.
• Accurately measures RMS voltage and current, power, power factor, frequency, energy, and total three-phase 15-minute power demand.
• Provides two isolated relays that close when the voltage phase relationships between the two monitored grids are within the specified ANSI 25 limits provided by the RX3i host controller. These contacts can be used for general-purpose, lamp duty or pilot duty loads. Voltage and current ratings for these load types are provided in GFK-2749, PACSystems RX3i Power Sync and Measurement System User’s Manual.
• Provides a cable monitoring function that indicates when the cables linking the PSM module and Terminal Assembly are correctly installed.
• PSM module and Terminal Assembly are easily calibrated by hardware configuration using the PAC Machine Edition (PME) software.

To find out how Novotek can help you reduce your energy consumption and manage multiple energy sources email us at info_uk@novotek.com

Since the beginning of the COVID-19 pandemic, businesses across the UK have faced a surge in cybercrime. In fact, research indicates that UK businesses experienced one attempted cyberattack every 46 seconds on average in 2020. Industrial businesses are a prime target for hackers and the ramifications of a data breach or denial-of-service attack are far-reaching, making system security imperative. Here, David Evanson, corporate vendor relationship manager at Novotek UK and Ireland, explains how industrial businesses can keep their vital systems secure.

For many business leaders and engineers, it is still tempting to consider large multinational companies or data-rich digital service providers to be the prime target for hackers. However, the growing volume of cyberattacks on businesses globally show that any company can be a target of malicious attacks on systems and services.

According to research by internet service provider Beaming, there were 686,961 attempted system breaches among UK businesses in 2020, marking a 20 per cent increase on 2019. Of these attacks, Beaming noted that one in ten intended to gain control of an Internet of Things (IoT) device — something that indicates a tendency to target system continuity rather than conventional data.

Both factors together are cause for alarm among industrial businesses of all sizes. Hackers are targeting all manner of companies, from start-ups to global organisations, and focussing more on the growing number of internet-connected devices and systems that were previously isolated.

The consequences of a device being compromised range from data extraction to service shutdown, and in any case the financial and production impacts to an industrial business are significant. There is no single quick fix to bolster cybersecurity due to the varying types of hacks that can take place. Some cyberattacks are complex and sophisticated; others less so. Many attacks on devices tend to fall into the latter category, which means there are some steps industrial businesses can take to minimise risk.

Novotek has been working closely with industrial businesses in the UK and Ireland for decades. One common thing that we have observed with automation hardware and software is that many engineers do not regularly upgrade software or firmware. Instead, there is a tendency to view automation as a one-off, fit-and-forget purchase. The hardware may be physically maintained on a regular schedule, but the invisible software aspect is often neglected.

Older firmware is more susceptible to hacks because it often contains unpatched known security vulnerabilities, such as weak authentication algorithms, obsolete encryption technologies or backdoors for unauthorised access. For a programmable logic controller (PLC), older firmware versions make it possible for cyber attackers to change the module state to halt-mode, resulting in a denial-of-service that stops production or prevents critical processes from running.

PLC manufacturers routinely update firmware to ensure it is robust and secure in the face of the changing cyber landscape, but there is not always a set interval between these updates.

In some cases, updates are released in the days or weeks following the discovery of a vulnerability — either by the manufacturer, Whitehat hackers or genuine attackers — to minimise end-user risk. The firmware version’s upgrade information should outline any exploits that have been fixed.

However, it’s important to note that legacy PLCs may no longer receive firmware updates from the manufacturer if the system has reached obsolescence. Many engineers opt to air-gap older PLCs to minimise the cybersecurity risk, but the lack of firmware support can also create interoperability issues with connected devices. Another part of the network, such as a switch, receiving an update can cause communications and compatibility issues with PLCs running on older versions — yet another reason why systems should run on the most recent software patches.

At this stage, engineers should invest in a more modern PLC to minimise risk — and, due to the rate of advancement of PLCs in recent years, likely benefit from greater functionality at the same time.

Firmware vulnerabilities are unavoidable, regardless of the quality of the PLC. At Novotek, we give extensive support for the Emerson PACSystems products that we provide to businesses in the UK and Ireland. This involves not only support with firmware updates as they become available, but also guidance on wider system resilience to ensure that businesses are as safe as possible from hardware vulnerabilities. The growth in cyberattacks will continue long beyond the end of the COVID-19 pandemic, and infrastructure and automation are increasingly becoming targets. It may seem a simple step, but taking the same upgrade approach to firmware that we do with conventional computers can help engineers to secure their operations and keep running systems safely.

In the age of connectivity, there is no shortage of useful information that engineers can leverage to optimise and improve operations. Everything from the speed of motors to the weather forecast can influence production. However, bringing these data sources together in a secure way is a challenge faced by many engineers. Here, George Walker, managing director of Novotek UK and Ireland, explains how engineers can bridge the gap between local process data and external data sources.

The Internet of Things (IoT) may still be a relatively new concept for many consumers and professional service businesses, but the idea of machine-to-machine communication and connectivity is nothing new for industry. In fact, it’s been more than 50 years since the programmable logic controller (PLC) first became popular among industrial businesses as a means of controlling connected systems.

The principle behind the PLC is quite simple: see, think and do. The controller will ‘see’ what is happening in a process based on the input data from the connected devices and machines. The PLC then processes this input and computes if any adjustments are required and if so, it signals these commands to the field devices. Traditionally, the field devices that could be controlled was limited, but recent developments in sensor technology have made specific components and resources much more measurable.

For example, if a water tank is almost at full capacity in a food processing plant, data from connected sensors can feed that information to a PLC. The PLC then sends the signal for the valve to close once the water volume exceeds a certain threshold, which prevents overflow. This is a simple control loop that sufficiently meets the need of the process.

Unfortunately, even as edge computing and PLC technology has advanced and offered more sophisticated data processing and control at the field-level, many plant engineers continue to setup their devices in this way. In reality, modern edge devices and industrial PCs (IPCs) are capable of providing much greater control, as well as responding to external commands or variables that were previously beyond the scope of control systems.

The outer loop

While the idea of the Industrial IoT (IIoT) is predominately a means of branding modern connectivity, the wider Industry 4.0 movement has brought with it some valuable advancements in edge and PLC technology. Among these advancements is the potential for on-premises automation and control systems to not only connect with local devices in an inner loop, but to draw from external sources: an outer loop.

The outer loop can take several forms, depending on what is most applicable or relevant to a process or operation.

For example, some more digitally mature businesses might have outer loops that feature an enterprise resource planning (ERP) system, supply chain management software or a wider manufacturing execution system (MES). These systems will share and receive relevant information or send required adjustments — such as due to raw material intake or low stock — to an edge device, which feeds into the inner loop. This allows industrial businesses to make use of more comprehensive data analysis than can be achieved in local data systems.

Alternatively, an outer loop could draw from data sources that are completely external to a plant’s operations. For example, a wind farm operator could use an outer loop that drew from sources of meteorological data for wind forecasts. This could inform the optimum pitch and yaw of a turbine, controlled by a field device.

Another example, and one that will resonate with many industrial businesses, is energy price. The cost of power from the electrical grid fluctuates throughout the day, which might mean that on-site generation — such as solar panels or heat recovery processes — become more economical during times of peak grid demand. An outer loop can communicate this data efficiently to the relevant systems in a business, and changes can then be enacted that allow the business to reduce energy costs.

Establishing secure connection

Clearly, there is a benefit for industrial businesses to establish both inner and outer loops. However, there is one barrier to deployment that most engineers encounter: hardware limitations.

Traditional PLCs were designed in a rather utilitarian manner to complete control functions effectively and in a straightforward manner. This no-frills approach persists even with modern PLCs — even with today’s technical specifications, most PLCs are not designed in a way that struggles to handle much more than a real-time operating system and some control applications.

Attempting to set up such a PLC to interact with an outer loop would either not work at all or severely hinder performance and risk failure.

Engineers can tackle this problem by introducing a separate gateway device that serves as an intermediary between the outer loop and the inner loop. However, this is a somewhat inelegant solution that requires investment in additional devices, which will require ongoing maintenance and introduce yet another device into already large system networks. Across an entire site, this quickly becomes costly and complicates network topologies.

A better solution is an unconventional one. It is possible to set up a modern automation controller in such a way that it breaks the conventions of PLCs, as long as the device is capable of multi-core processing at pace. From Novotek’s perspective, one of the best modern units that meet this need is Emerson Automation’s CPL410 automation controller.

The CPL410 can split inner and outer loop processing between its multiple processor cores. The inner loop and PLC processes can run from a single core, while another core — or even a group of cores, depending on complexity — can run more sophisticated containerised applications or operating systems. Additional cores can broker between the inner and outer loops, ensuring reliability and security.

A multi-core setup is useful because it allows the PLC processes and gateway to be consolidating into a single unit, without compromising performance capacity or speed. It also means that ageing or obsolete PLCs can be upgraded to a controller such as the CPL410 during any modernisation initiatives, minimising additional capital costs.

Although the idea behind the IoT is not a new one for industrial businesses, the fact that other sectors are embracing the idea means more external data points than ever before are available. With systems in place that can support effective inner and outer loops, industrial businesses can leverage the increased connectivity of external markets and enhance their own operations.

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It’s no secret that IPCs play an essential role in modern industrial operations. These vital units undertake a range of tasks, from managing equipment performance data to motion and automated system control. It’s therefore no surprise that the IPC market continues to go from strength to strength. In fact, ResearchAndMarkets forecasts that the global IPC market will grow at a compound annual growth rate (CAGR) of 6.45 per cent, to be valued at $7.756 USD by 2026.

IPCs feature prominently on the factory floor, generally either in control cabinets or mounted onto machinery. Being on the frontline means that engineers and plant managers know that, as a minimum, they need to specify ruggedised IPCs for their operations. What sometimes gets overlooked, however, is the operating temperature range of an IPC unit.

Electronic circuits and computing components are highly susceptible to extreme temperatures, be they high or low. At high temperatures, components can deteriorate faster. In the case of IPCs, modern CPUs are designed to prevent accelerated component deterioration by throttling their processing performance. This succeeds in reducing the heat produced in processing circuits, but it means that processes running on the IPC run slowly or become unresponsive — not ideal for real-time control applications.

In certain markets, considering operating temperature range is second nature for engineers. For example, an IPC tasked with controlling or collecting data from a welding robot will be specified to withstand high temperatures.

However, temperature should be a consideration even in unassuming industrial environments. If an IPC is situated outside, the exposure to sunlight — alongside reduced airflow in an installation — can cause an increase in temperature that can reach up to 70 degrees Celsius. Both Novotek and its partner Emerson Automation have encountered industrial businesses that have experienced this problem.

Of course, the solution to the challenge of overheating in IPCs is to specify a unit that boasts good thermal performance in an extended operating temperature. Unfortunately, not all IPCs that claim to offer this feature are actually effectively tested in conditions that accurately reflect real-world operating conditions, which can lead to some IPCs failing when deployed in the field.

The reason why extended temperature IPCs fail is due to the way that the testing is undertaken. In many cases, the IPC is tested in a thermal chamber that has significant forced air flow conditions, which reduces the efficacy and the accuracy of the test itself. A more effective way of testing is for the IPC manufacturer to block the airflow, which simulates a realistic use condition in a cabinet environment.

Emerson Automation conducts its tests under these restricted airflow conditions, which allows it to accurately demonstrate that its IPCs can perform at high temperatures without throttling processing performance. The company has even shared a video of its IPC thermal testing process, highlighting the capabilities of its RXi2-BP.

It’s for this reason that Emerson’s IPCs are the go-to option from Novotek’s perspective, because they ensure reliable and consistent operation in demanding environmental conditions.

With IPCs playing such a vital role in modern industry, its important that they are up to the task not only in terms of computing capacity, but also environmental performance. When plant managers and engineers can specify an IPC with assurances of the accuracy of thermal testing, it provides peace of mind that the unit can handle the heat.

An annual report by Kaspersky Lab, The State of Industrial Cybersecurity 2018, revealed several interesting facts about how industrial cybersecurity is perceived by businesses and applied to Industrial Control Systems (ICS). The survey of 230 worldwide professionals reveals disconnections between what is feared by businesses, and what’s happening in reality.

For instance, 66 per cent of the surveyed businesses were most concerned about advanced persistent threats (APT), like data leaks and spying (59 per cent), because of their perceived potential impact. In reality, APT’s make up 16 per cent of cybersecurity incidents. Actually, conventional malware and virus outbreaks are becoming the greater problem. These attacks are not overly sophisticated and made up 64 per cent of cybersecurity incidents, last year.

Aside from misconceptions about the external threat landscape, disparities also exist within organisations. In relation to Kaspersky Lab’s survey, technology website tripwire.com cited a report by the SANS Institute. SANS found that, among nearly three-quarters of firms that were confident in their ability to secure their industrial internet of things (IIoT), there were more likely to be different internal perceptions about the effectiveness of their security measures. While leaders and department managers were more likely to have a “rosy outlook” of their security, operational technology departments had a more pessimistic view.

Such misconceptions would be even more of a concern within critical national infrastructures. Cyberattacks against water, energy or chemical supplies can have very real consequences for countries and their populations.

Upgrading control systems

From a hardware and systems perspective, more than half — 54 per cent — of the surveyed businesses identified integrating ICS with IT systems and Internet of Things (IoT) ecosystems as among the most pronounced challenges. This last statistic places a wider challenge faced by plant managers into a whole new context: specifically, how best to achieve space and cost savings by reducing the size and complexity of plant equipment.

Plant managers are turning to new systems to achieve greater levels of flexibility and profitability in their production. This coincides with older programmable automation controller (PAC) systems, like trusted Series 90-30 controllers, reaching the end of their operational lifespans. In many cases, these 90-30 systems have been relied upon as integral to plant operations for upwards of 25 years.

How can plant managers effectively upgrade their systems, while ensuring that cybersecurity measures keep up with the rate of technology adoption — and the external threat landscape? Fortunately, answers lie in smart hardware and its role in helping manufacturers enhance process flexibility and performance.

Centralised security

One solution lies in better control. The RSTi-EP CPE100 is a compact controller for PAC systems — specifically, to control the RX3i CPU from Emerson which has emerged as a popular and effective upgrade for 90-30 systems. In a nutshell, the RSTi-EP CPE100 leverages the power and flexibility of PAC systems in smaller applications.

The RSTi-EP CPE100, entire PAC systems can be programmed in stand-alone applications, or the system can be used as an auxiliary controller in larger process applications that use the RX3i. Not only does the system leverage the power and flexibility of PAC systems in smaller applications, there are also benefits in terms or cybersecurity — indeed, the RSTi CPE100 is secure by design.

With the system, companies can apply optimised security right from the very start. RSTi CPE100 incorporates technologies like Trusted Platform Modules and secure, trusted, and measured boot. It allows centralised configurations, so that encrypted firmware updates can be executed from a secure central location. Specifically, a suite of cybersecurity technologies can help prevent unauthorized updates. Meanwhile, built-in security protocols can protect against man-in-the-middle attack (MITM) — where the attacker secretly inters with communications between two parties — and denial-of-service (DoS) attacks.

Speaking of the “man-in-the-middle”, another key takeaway from Kaspersky Lab’s report is that, going forward, industrial companies must also pay more attention to employees’ understanding and awareness of cyber threats. Because the RSTi-EP CPE100 can streamline application development and integration, a further benefit of the system is that it simplifies training for operators and maintenance workers.

While cyberattacks on ICS computers are misunderstood by many within industry, it’s necessary to overcome these misconceptions while keeping up with the best cybersecurity measures. Novotek recommends that managers should pay attention to system security from the very beginning of their integration. The more critical the application, the more important it is that ideas surrounding cyberattacks accurately pre-empt the realities.