SCADA helps keep road tunnel traffic safe and free flowing

Traffic flow and safety have been enhanced in one of Italy’s most important motorway tunnels by the commissioning of a new control system based on Products4Automation’s Movicon 11 SCADA technology.
Because of the country’s mountainous landscape, road tunnels are an important part of Italy’s transport infrastructure. Each tunnel has its own unique traffic management system to handle the safety and security requirements involved with their operation. Because of the ever growing usage volumes as the number of cars on the road increase each system needs to be regularly maintained and developed. Bespoke control solutions are usually specified for each tunnel; programmed for the unique challenges each one presents.
When engineers for the Spogliamonaco Tunnel on the Lauria–Lagonegro motorway in Basilicata were looking to renew their control system, they wanted to develop a system which allowed for both local, on-site control and remote control from head office. They identified a bus architecture and SCADA software as the optimum solution and also wanted an open system so that they could mix and match hardware from different manufacturers – a critical requirement for a system that could be operating for decades.
The architecture the engineers developed consisted of a central PC acting as the overall supervision and control unit. The decision was made early on to design out other local controllers such as PLCs or CPUs, as the simplicity of the system would help contain initial costs and ensure maintenance was straightforward. Instead they ran a single bus the whole 1500m length of the tunnel, with all the I/O nodes distributed along it.
When it came to selecting the SCADA (supervisory control and data acquisition) software many options were considered before eventually deciding that the Movicon 11 system was most appropriate to their needs. Movicon 11 is XML-based and combines SCADA with an HMI (human machine interface), which means it offers an all-in-one development environment for managing HMI, SCADA, soft-logic and analysis of operating data. It is also open and highly flexible, and attractive feature in an application where constant design evolution is to be expected.
The I/O control is based on Windows XP, which is freely available, well supported and low cost. Windows XP is not deterministic (able to absolutely guarantee the sequence and speed of signal processing); but this is not a requirement in tunnel control systems, as no instructions are completely time critical. Instead a LonWorks card fitted in the PC handles all the data traffic from the 110 I/O nodes on the bus.
LonWorks is an open networking platform that is used worldwide in a range of automation applications, including many in building automation and HVAC environments, as well as in other tunnel control systems. There are a great many brands and models of hardware products available that are compatible with LonWorks including high power lamps, emergency lighting, ventilation fans and water pumps.
In the Spogliamonaco Tunnel installation, the Movicon SCADA system constantly monitors all the data produced on the bus for alarms, such as failed lamps, and trending towards critical conditions such as rising carbon dioxide levels. It is also able to monitor other parameters such as dangerous vibrations (e.g. earthquakes and rock falls), reduced visibility due to excessive exhaust, wind speed and direction, ventilation extraction rate, CCTV and several other functions.
Many functions are automated by the Movicon system, freeing the staff in the control room from routine duties so that they can concentrate on higher level activities. From the supervision stations, situated both in the local control stations and in the main control centre, operators can monitor the full length of the tunnel as well as facilities at each end, using screen pages that display both current and logged data.
All the commands can be easily and intuitively set by mouse-clicking on the on-screen graphics. For example, the traffic lights that control vehicle movements are normally run automatically by the Movicon logic control function, but users can assume manual override should the situation require it. The same is true of the ventilators and other critical equipment.
All operating data is logged by the SCADA software, and can be analysed for alarms, trends etc. This leads to optimisation of operations and helps to maintain efficiency and smooth traffic flow.
The engineers have also programmed the Movicon SCADA to provide enhanced management of the maintenance programmes. Optimising the work schedules for the maintenance technicians can be complicated because some equipment - such as the lamps - is maintained to regular time schedules while other equipment – such as the fan – is maintained based on usage. Added to this there is the need to attend failures and breakdowns. By working this out automatically equipment is better maintained and people’s time and resources are used to the best advantage.
The Spogliamonaco Tunnel has always been fitted with landline telephones, giving personnel a straightforward and effective means of communication. These landlines have been integrated into the SCADA system so that their use is logged alongside the rest of the operating data. The SCADA also has the capacity to send text messages and pre-recorded mobile phone messages to staff who are ‘on-call’.
In summary, Movicon has provided an innovative tunnel control solution that facilitates rapid development at low cost, yet which still functions at a high level and with simplicity.

Article source -  http://www.dmaeuropa.com/Clients/Products4Automation/News/tabid/1233/itemid/2246/Default.aspx

About P4A

Products4Automation (P4A) is a specialist supplier of new and innovative software and hardware solutions to the UK market. Products ranges available from P4A include the latest touch-screen HMI's and flat panel PCs, SCADA software and plug-ins, a wide range of SCADA enabled hardware, Alarm plug-in software for large automation systems, and a full range of Production Intelligence software solutions.

 To receive your free development CD and information pack click here

CREAMERY UPGRADES WITH MOVICON SCADA

Parmareggio Unigrana has used Product4Automations’ low cost Movicon 11 SCADA to automate one of the creameries that has helped it become a major butter producer, as well as world-famous for its cheese.
With demand for the region’s butter soaring (up 22 percent in 2011 to Euro35m) the decision was made to automate the Fiordalba creamery in Modena, to increase production, guarantee quality and ensure efficiency. To maintain quality and originality many food products from this area of Italy have special Protected Designation of Origin (PDO) status.
The creamery’s systems design and installation was entrusted to I.T. Technologies Srl, a Movicon integrator that works extensively in the region. The plant, which was already partially controlled by Movicon equipment, was to be fully automated, including installation of a new SCADA (supervisory control and data acquisition) system. This would improve the system redundancy and add a quality certification capability. Many other new systems were also installed on the production floor, while some existing systems were enhanced with extra functionality.

Butter production
Fresh cream is the raw material used for making Parmareggio butter. This comes directly from regional PDO dairies which themselves use automation systems to guarantee security and quality. Close relationships are maintained with suppliers, often built up over decades, to ensure product integrity.
The cream is first put through a centrifuge where it is mixed with water and melted butter. It is then pumped into a storage tank from which it is collected and sent onto be skimmed. From here it is immediately sent on to a pasteurisation plant. This delicate process cycle is constantly monitored and recorded by the Movicon SCADA system to ensure compliance with stringent European food safety standards.
Once pasteurised, the cream is left to settle naturally in vats. During this phase the temperature is constantly controlled in order to obtain a perfect end product with an easy spreading consistency. After this it is pumped on to ripening tanks where it cooled and remixed then pumped on to the butter making machines, where it is churned while milk enzymes are gradually. This thickens the cream to make butter. Separated buttermilk, a useful by-product, is sent to a separate pasteurising process then stored in silos to await collection for other processes.
A sophisticated NIRS (Near Infrared Reflectance Spectroscopy) system working with the SCADA constantly controls the all the products’ chemical parameters.

Packaging
The butter is automatically transferred to the packaging area. As with the rest of the production, this phase uses completely enclosed and automated equipment to prevent the risk of product contamination from operators or the environment.
The high speed lines are able to package butter in all shapes and sizes according to market demands. They are also equipped with automatic weight control systems.
With all the production and packaging processes complete, the butter is placed in a refrigerated storeroom where temperatures are constantly monitored and recorded until all the product quality controls of each batch have been double checked by the Quality Control Office. Security and food quality are always maintained at maximum levels during this stage.

Plant and control
The entire production plant is controlled by a Movicon 11 SCADA system implemented on three Siemens S7 PLCs built into stainless steel control panels in a central control room and connected via Ethernet. One PLC manages the production process system; the other two manage the CIP (cleaning in place) systems and the storage systems. Together they guarantee maximum security during the different production stages. They also measure operational and chemical parameters, which are mainly determined by temperature and the product’s micro-organic profile.
The control system also includes a number of Movicon HMIs or graphical screen which can display pages for every process within the plant, covering critical parameters for quality, hygiene, productivity and maintenance. The HMI screen pages are all divided into two frames, one containing operational statuses, the other containing operational command sequences.

Perfect hygiene
The control system also runs an automatic Clean-In-Place CIP system, which is fully integrated with the production processes and implements cleaning processes without any disassembling of the plant or its parts.
The cleaning system ensures uniform treatment of surfaces that have direct contact with product, while damage to mechanical parts is avoided. Further there is no risk of contamination while the plant is disassembled. The cleaning is scheduled automatically and all cleaning data is stored for traceability. The overall objective is for efficient and effective cleaning and to fully meet the FDA and health and quality standards.
The CIP system uses comprehensive detergent recovery to ensure product quality. The recovered washing liquid is collected so that it can be regenerated and reused, a critical principle for maintaining the highest environmental standards. Again, all data is recorded.

Redundancy
The main control room also accommodates two additional PC stations, which run Windows 7 with Movicon 11 setup in a redundant configuration. Both PCs are constantly updated and each backs up the other, including recording of all data for track and trace requirements. This guarantees maximum availability and continuous 24 hour running of the creamery.
Thanks to the redundancy system, the operating personnel have two workstations. These can be used independently; for instance, an operator may be using the first to monitor a cream collection tank and start a cleaning process, while his colleague checks skimmer operations and prints out a product quality report.
Communication within the control system is based on Movicon S7-TCP communication drivers, which collect and aggregate data in a Real Time Database residing on an MS SQL server.
The production process is managed visually on the HMIs, from where instructions can also be sent. These instructions are collected on the database, no matter which HMI the come from.
A predictive alarm management programme follows trends within the accumulating data to pre-empt malfunctions and provide step-by-step guidance on appropriate corrective/maintenance procedures.
The system runs the plant in compliance to the FDA CFR21 part 11 regulations. These are normally associated with pharmaceuticals production, but are also used for high quality food operations. They are designed to control access to plant and product to authorised personnel only.
Movicon has a simple but very sophisticated user and command access management system explicitly designed to support the CFR21 Part 11 regulations. In addition to all the requirements defined by the user privileges (area and access level), the system manages ‘electronic signatures’ in reports and for historical data. This way, each significant action executed in the plant, such as commands or target parameter modifications can be traced back to an individual person. Audits are recorded in the database with encrypted access and can be documented appropriately in reports.
The creamery continued to run throughout the whole installation process, which was completed quickly and efficiently thanks to the I.T. Technologies technicians’ vast experience and the rapid design and configuration ability of the Movicon platform.
Parmareggio has achieved its target productivity rate and is set to maintain strong growth well into the future.

 Article source - http://www.dmaeuropa.com/Clients/Products4Automation/News/tabid/1233/itemid/2230/Default.aspx

About P4A

Products4Automation (P4A) is a specialist supplier of new and innovative software and hardware solutions to the UK market. Products ranges available from P4A include the latest touch-screen HMI's and flat panel PCs, SCADA software and plug-ins, a wide range of SCADA enabled hardware, Alarm plug-in software for large automation systems, and a full range of Production Intelligence software solutions.

 For more information on SCADA HMI solutions and production software please contact us

XML-based HMI brings increased flexibility and functionality to new shrink wrapper machine design

When specialist packaging machine builder Kosme looked to adopt a new SCADA/HMI standard platform to provide control and visualisation for its new Flypack shrink wrapping machine, it turned to the XML-based Movicon SCADA package, supplied in the UK by Products4Automation.
Established in 1981, Kosme is a leading producer of packaging machines, including packers, palletisers, depalletisers, blowmoulders, wrappers and carton sealers, from single machines right up to complete production lines. With its unrivalled industry insight, Kosme saw an opportunity for an innovative new style of shrink wrapper built on a modular platform, featuring a compacter unit, a wrapping unit and a heat shrinker tunnel. Built with a tray erector and a layer pad inserter module, it would also be able to handle trays and film packs.
The machine would not only set new benchmarks for performance, with speeds of up to 45ppm, but would also deliver best-in-class control interfaces for improved operator control, faster product changeover and simpler servicing. This would see the Flypack system divided into an ‘operator side’ and a ‘service side’. The operator side would provide all the handwheels for format changeovers and the operator HMI. All of the serviceable components would be located on the service side.
To deliver the level of control required by the operators with the degree of modularity required to build such flexible machines, Kosme knew it needed to reassess its control strategy, moving away from fixed format controllers. Kosme’s R&D Group was looking for an alternative approach that would deliver the increased flexibility required combined with a significantly lower cost of development, while providing the levels of functionality and graphics that are essential for enhanced and intuitive operation.
To meet these requirements, Kosme investigated Progea’s Movicon SCADA software. Movicon SCADA/HMI technology is the only package of its kind to be completely based on XML standards and emergent technologies such as Web Services, SVG graphics, SOAP, OPC, SQL, .Net and COM, and Java. Movicon promised the ability to create user interfaces with vastly improved graphics, independent of screen size and resolution, making machines much more intuitive to operate and delivery richer functionality.
A move to Movicon also delivered the level of modularity that Kosme required in order to reduce the resources that would need to be deployed in planning and maintaining not only the Flypack but also any subsequent machine designs. In addition, by providing identical graphical interfaces and functionality on both Windows XP Embedded and Windows CE platforms, Movicon would allow Kosme to adopt whichever was more suitable for a given machine design without having to worry about porting an HMI to a different platform.
Developing the machine control interface around Movicon allowed Kosme to take a modular approach to machine design for more flexible operation. The Flypack shrink wrapper can provide a choice of packaging modes that include film only, tray only, film plus tray or film plus layer pad options. The container formats are also very versatile, covering bottles, cans and containers, and can be produced in any size and supported material including PET, glass, aluminium and more.
Movicon also gave Kosme the flexibility to meet the specific needs of individual customers of the Flypack shrink wrapper, making it easy to incorporate user specific functions. These included support for dynamic language change, user and password protection management compliant to FDA CFR21 Part 11 regulations, and alarm notifications by SMS or email.
Other optional functionalities can be enabled at any time on existing installations without any modification to the project, enabling control systems to evolve easily with changing customer requirements. These features include tracking, production reporting, statistics, web connectivity for remote access to the visualisation system, and the ability to access the system as a client from a mobile phone.
The Flypack shrink wrapper is not only an innovative addition to Kosme’s product range, but has also been hailed as a breakthrough product within the packaging industry generally. With its modular design and advanced HMI system providing significant user advantages, Flypack shrink wrappers are now being delivered and used all over the world.
For Kosme, the switch from conventional fixed format solutions to the more flexible XML-based Movicon approach has delivered machines which offer new standards in functionality and ease of use, and which are simpler to maintain and easier to service. At the same time, the switch to Movicon has significantly reduced Kosme’s machine development costs while providing the ability to respond to specific customer requirements.

About P4A

Products4Automation (P4A) is a specialist supplier of new and innovative software and hardware solutions to the UK market. Products ranges available from P4A include the latest touch-screen HMI's and flat panel PCs, SCADA software and plug-ins, a wide range of SCADA enabled hardware, Alarm plug-in software for large automation systems, and a full range of Production Intelligence software solutions.

For further information contact: Products 4 Automation Limited 

Article source -  http://www.dmaeuropa.com/Clients/Products4Automation/News/tabid/1233/itemid/2169/Default.aspx

MOVICON 11 SCADA PROVIDES SUPERVISORY CONTROL & MONITORING AT LARGEST BIOMASS POWER STATION IN ITALY

The largest agricultural biomass power station in Italy was commissioned recently, with supervisory control and monitoring provided by Progea Movicon 11 SCADA. Paul Hurst, MD of Products4Automation, Movicon’s UK distributor, describes the new system and outlines the benefits of using Movicon SCADA in sustainable energy generation projects.

“The new Bondeno power plant is built on area covering nine hectares, and has four 1 MWe power stations, providing an overall 4 MWe of installed power to supply around 10,000 households each year. It runs on biogas, which is produced by biological fermentation of products such as maize, sorghum and wheat. The biogas is 55% part Methane, which is sufficient to feed the four SINCRO 1000 cogeneration motors installed at the station.

In many ways biogas is the ideal fuel, due to its neutral CO2 effect on the atmosphere. This is because the amount of CO2 emitted by the biogas is equal to the amount absorbed by plants (or consumed by animals indirectly when feeding on plant vegetation). The use of biogas therefore becomes part of the plant carbon cycle, without adding to the greenhouse warming effect, unlike other types of fossil fuels.

The complexity of the biogas production process meant that choice of plant automation system was crucial. The system is essential for monitoring, efficient management and maintenance, as well as analysing historical performance system data. The choice of system was made by CPL Concordia, project engineers for the Bondeno plant. CPL Concordia is a multi-utility co-operative group, which has over 30-years experience in the renewable energy sector.

Alessio Vaccari, the head of the CPL’s Congeneration software department, was tasked with finding the best system. He carried out a technical survey to evaluate the most suitable software platform to use. Finally, he chose Movicon 11 Scada/HMI technology, which was judged as being ideal for achieving CPL Concordia’s set objectives.

read more: http://www.dmaeuropa.com/Clients/Products4Automation/News/tabid/1233/itemid/2038/Default.aspx

P4A’S MOVICON SYSTEM PROVIDES FULL SCADA ‘FOR PRICE OF HMI’ ON NEW STATE-OF-THE-ART-PLATING PLANT

Products4Automation’s low cost Movicon SCADA has been chosen to control a new state-of-the-art Electrophoretic Coating plant, recently installed by the Foleshill Plating Company of Coventry. The project, to control and monitor all aspects of the new plant, including logging and trending in Excel format, web access monitoring by IPad and IPhone and email alarming, was supplied by P4A Movicon system integrator, S&H Systems of Cannock.

The Foleshill Plating Company is one of the UK’s top plating and metal finishing companies, serving key industry sectors, such as automotive. Key to the company’s success are its reputation for quality, and the fact that it offers very fast lead times: the latter as a result of investment in fully automated process lines that run 24- hours a day.

Recently, Foleshill has added to its automated lines with a new Electrophoretic Coating plant. This has been installed to provide high quality finishes across larger components that were previously beyond the company’s capacity. The principal purpose of this coating is anti-corrosion protection; it also provides an excellent surface preparation for subsequent elements of the paint system.

The project to automate, control and monitor the new coating plant was awarded to S&H Systems a company with over 20- years experience in the design, project management and installation of electrical works and control systems, including electrical control panel design and manufacture.

The S&H engineer in charge of the project was Bryan Garbett. He takes up the story. “The Foleshill project involved us in supplying a PLC control system with a supervisory data acquisition and control system (SCADA), and eight inverter drives to control the motors that drive the transporters for component transfer. We decided on an Allen Bradley PLC and drives; but when we came to specify and price the SCADA system, the costs for the most well known packages were prohibitive. To overcome this problem, we asked Paul Hurst at P4A for an equivalent quote, using Movicon SCADA.

This turned out to be around 40% below our original quotations; effectively giving us a full SCADA package for the price of an HMI- based system from competitive vendors. What’s more, the Movicon system was incredibly easy to use, and offered much, much more for the price. It included an integrated Historian, and trending functions, really excellent communications functions – and, crucially, had no development costs.”

read more: http://www.dmaeuropa.com/Clients/Products4Automation/News/tabid/1233/itemid/1998/Default.aspx

Siemens squashes Stuxnet-like bugs in SCADA kit

Siemens has corked vulnerabilities in its industrial control kit similar to those exploited by the infamous Stuxnet worm.

Security bugs on the German manufacturer's Simatic Step 7 and Simatic PCS 7 SCADA control software created a means to load malicious dynamic-link library (DLL) files. This is the type of flaw exploited by the Stuxnet worm, which used DLL hijacking techniques in Step 7 software to infect systems controlling high-speed centrifuges at Iranian nuclear facilities. It is not clear, however, whether or not this specific bug was used in the Stuxnet attack.

Siemens said that previous versions of its Step 7 and PCS 7 software allowed the loading of DLL files into the Step 7 project folder without validation – giving the malware free rein to attack the SCADA systems. The firm fixed the flaw by introducing a mechanism that rejected the loading of DLL files into the folder – effectively blocking the path to possible infection, an advisory by the Industrial Control Systems Cyber Emergency Response Team (ISC-CERT) explains.

A second update, also released on Monday, deals with a SQL server authentication security flaws in Siemen’s Simatic WinCC and Simatic PCS 7 software. Left unfixed, the vulnerability created a means for hackers to get into targeted systems using default credentials.

Siemens issued a series of patches in the wake of the discovery of the Stuxnet worm back in 2010 but this failed to placate critics, including Ralph Langner, who claimed last year that many shortcomings in Siemens' supervisory control and data acquisition (SCADA) systems remained unpatched.

Stuxnet used an array of Windows-based zero-day flaws, configuration weaknesses and security bugs in SCADA systems to infect a system and spread across it. So even though the main Windows-based attack vector was patched relatively quickly, concerns remain about the security of industrial controls software, which is often overlooked when it comes to patching.

read more: http://www.theregister.co.uk/2012/07/25/siemens_scada_security/

12.1-inch Open-Frame Panel PC for Industrial Applications

Arlington, TX (PRWEB) July 12, 2012

WinSystems introduces a 12.1-inch open frame, color flat panel PC and 1.66GHz single board computer (SBC) based on the Intel® Atom™ processor. The PPC3-12 panel PC is a compact, ready-to-mount flat panel display subsystem that also includes a resistive touchscreen integrated into a chassis less than three inches deep. The open frame (i.e. without a front bezel) chassis permits flexible mounting of the system for OEMs and integrators with tight system integration and minimal space requirements.

The PPC3-12 is perfect for networked applications since it is shipped with a wired Ethernet connection plus expansion option for 802.11 wireless Ethernet and/or CDMA/GSM cellular modems. The unit will operate from -30° to +70°C without the need of a fan. The combination of embedded PC functionality, industrial-grade construction, small size, and wide operating temperature range makes the unit ideal for medical, transportation, instrumentation, kiosks, industrial automation, security, and control applications.

A high-luminance, wide-viewing angle, 12.1-inch diagonal color TFT with replaceable LED backlight is the foundation of the Panel PC. It supports XGA 1024 x 768 pixels that can display 16.2M (8-bit RGB) or 262,144 (6-bit RGB) colors. This flat panel display has a high luminance of 500 cd/m² (typ.). It uses long-life LEDs as edge lights which are user replaceable. The display supports a viewing angle of ±80° (typical) for both horizontal and vertical. This wide viewing angle permits easy panel placement with maximum operator viewing flexibility.

WinSystems offers a single core 1.66GHz N455 and dual core 1.8GHz D525 version of the SBC to serve as the computing and display engine for the Panel PC. Both SBCs are based on the Intel® Atom™ processor family with a full set of I/O interfaces including two Gigabit Ethernet ports, VGA and dual channel LVDS flat panel video, miniPCI connector to support wireless networking modules, eight USB 2.0 ports, four serial COM ports, 48 digital I/O lines, audio, LPT and PS/2 port for keyboard and mouse. The board also has PC/104 and PC/104-Plus connectors for support of additional off-the-shelf or user-designed specialty I/O modules.

Read more: http://www.digitaljournal.com/pr/792571#ixzz20RW3JX8y

Take a fresh look at your system security

Industrial automation networks differ greatly from office networks and, as such, need a different approach to safety and security, as Paul Hingley explains

Alittle known organisation called the CPNI (Centre for Protection of National Infrastructure), along with other government agencies, spends a great deal of time and effort offering practical advice to some of the businesses supporting the UK's major infrastructure requirements. Road, rail and transport industries, power generators, energy providers and water utilities are all potentially high risk in terms of threat. Any type of incident, attack or failure occurring within them would have potentially devastating consequences.

However, it isn't just this type of business that needs ongoing risk assessment and protection of SCADA networks. The same methodical preparation, thinking and implementation should also be front of mind for any manufacturing or process-driven business that could be at risk of attack or production failure. Company systems can be open to any number of threats and, once attacked, it is often too late to retrieve a situation. Think, for example, of a food manufacturer whose quality control procedures are compromised, or an industrial process targeted by environmental, political or animal rights protestors. Conversely, internal threats may appear, either accidental or intentional access violations, or virus introduction. It is my view that many businesses are at best complacent, and at worst potentially negligible, when it comes to protecting themselves and safeguarding their industrial networks' health, particularly when focusing upon automation networks. 

read more: http://www.worksmanagement.co.uk/works-management-supplier-spotlight/system-security/43123/

Smart Grid, Advanced Distribution Management Systems

Not everyone agrees on a precise definition of the smart grid, but most agree the modern grid will become increasingly complex.

As new kinds of loads, sources and equipment are implemented, the nature of the distribution network might evolve from a radial, one-way commodity delivery system to a bidirectional one. As the modern grid grows in sophistication, the need to plan, engineer and operate the network more effectively is critical. Enter advanced distribution management systems (ADMSs). Innovations in distribution management systems (DMSs) are helping address network complexity and making the smarter grid a reality.

A Revolution in DMS

DMS isn't new. Some utilities have used computers to model their networks for nearly four decades using load-flow algorithms to calculate voltages and power flows at nodes throughout the network. More recently, say, for the past 25 years, supervisory control and data acquisition (SCADA) systems have monitored and controlled the grid at key locations such as substations in real time. More recently, DMS combined the two ideas, solving the network model with using a load flow while accessing key real-time data points to enhance the picture of the grid.

As good as they were, first-generation DMSs can't cope with the requirements of a smarter grid. To safely and reliably operate, the modern grid needs a brain with capacity and functionality.

read more: http://www.elp.com/index/display/article-display/6152371337/articles/utility-automation-engineering-td/volume-17/issue-6/features/smart-grid-advanced-distribution-management-systems.html

NGCP puts up P147M control center

National Grid Corp. of the Philippines (NGCP) has invested P147 million in building a new power control center for the Mindanao grid.

This is expected to result in a more efficient, reliable and secure grid operations in the area.

According to NGCP, the Mindanao Regional Control Center, which is based in Cagayan de Oro City, will serve as the nerve center for grid operations in Mindanao. It will be equipped with modern power monitoring and control systems.

The new building houses the so-called Scada/EMS systems and telecommunications equipment and the office of the Mindanao system operations, which was previously based in Iligan City.

Scada, or Supervisory Control and Data Acquisition, refers to a collection of computers, equipment and application software integrated into a system to acquire real-time data on power system parameters and to provide monitoring and control facility for remote devices such as breakers.

The EMS, or Energy Management System, is composed of a Scada system with integrated advanced applications used in the management of the power grid.

The move to transfer the control center to the cities and away from the far-flung areas where they were usually located was patterned from the model used in China by one of NGCP’s owners, State Grid Corp. of China.

“Carmen, Cagayan de Oro City, was selected as the new site for being the nearest and most accessible to customers and stakeholders, an international airport, commercial amenities and military and police installations, which will be able to respond to any emergencies at once,” the NGCP said.

read more: http://business.inquirer.net/61921/ngcp-puts-up-p147m-control-center

The future of SCADA-control security

f you're a CXO overseeing a critical infrastructure that contains SCADA (supervisory control and data acquisition) controls, a chief concern is how to protect the infrastructure against terrorist attacks. Changes in control software will continue to accelerate until the most critical infrastructure weaknesses (oil refineries, electrical power plants, water treatment facilities) are addressed worldwide. But it may take years to replace all of the controls.


n order to address some of these concerns, networking vendors are deploying solutions to monitor network traffic between the management systems of these controls to determine the validity of its state. They can plan on implementing authentication and access controls on the sessions that communicate with the controls. As a newer generation of controls is deployed, authentication and authorization features will be built into the controls themselves. All access can be logged to determine if there is any tampering.

Read more: http://www.pcadvisor.co.uk/news/security/3355695/future-of-scada-control-security/#ixzz1umpadtAX

Movicon 11 SCADA Provides OEE Global Supervision Platform for Multi-National Confectionary Manufacturer

When GIMA Spa, a pioneering company among system manufacturers in the “Packaging Valley” region of Bologna in Italy, was asked by WRIGLEY, a world leader in confectionery manufacture, to provide a standardised supervisory system that would provide OEE data across all its different client product lines, the company turned to Progea’s Movicon 11 SCADA for a solution.

The challenge required designing an auto-configurable system that was capable of connecting to machines independently of their type and configuration. This meant that a modular and flexible software platform was required: one that was capable of managing an all-in-one standard project, and designed to connect to any product line machine, irrespective of type or number employed, to obtain the necessary information on production status and provide analysis on productivity efficiency.

The Movicon Scada/HMI platform was chosen as the ideal solution for achieving the stated system objectives, and of reaching the pre-planned production goals quickly and safely. Although working on a limited budget, GIMA Spa not only satisfied their confectionery client’s needs using the Movicon platform, but is now able to provide the standardised ‘added value’ system that the company engineered to other clients, including those from completely different market sectors.

“Zero” Maintenance Supervision
The production line supervision and analysis system based on Movicon has been designed to interface to a number of machine variables, not exceeding ten in number. The machines can be fitted either with a Siemens or Elau control units, both offering immediate project auto-configuring to machine production requirements, without requiring additional input or modification.

OEE and Downtime Statistical Analysis
The system’s task is to connect to the machines and highlight working statuses; display alarms - defined as ‘blockers’, and store all significant data, construed as alarms and production data.

This data is collected and displayed on the appropriate graphical summary screen pages, providing a clear overall picture of ongoing production situations in real-time, to enable managers to control the production process far more efficiently.

The main Movicon supervisor page informs users about production status, by representing the production line machine images graphically and by supplying data on: Batch number IDs; Product Settings; Product type; Batch name assigned by customer; Set quantity of units; Quantity of units produced; Unit percentage Produced; Production line working time of current batch; Production line speed; and the Time allotted for operatives working the current shift.

A screen page is provided for each machine in the system and these pages, when ‘clicked’, show all details and information relating to that production station. Complementing these pages, production line graphics appear automatically in conjunction with the number of machines enabled and operating in the production line at any particular time. A proprietary designed page has also been provided to manage production line batches and work shifts: the machines having been programmed to begin working only when assigned to a production batch. This is complemented by a production batch data import/export function to MsExcel formats facility.

The main objective is to record all data in database archives (Ms SQL Server 2000 was chosen from the various formats provided by Movicon) for performing statistical analysis that allow the end user, and builder, to obtain historical information in order to evaluate critical areas and intervene appropriately to improve production, reduce machine downtimes and increase the overall productivity index.

The supervisor performs statistical analysis on recorded data by managing:

• Alarm statistics (frequencies, durations) displayable both in table and graph format.
• Statistical graphics of on line productivity (includes a pie chart based on 100% time=shift; a general product line pie chart; and one for each machine, together with machine MTBF, MTTR, MDT indices)
• Tables for displaying production counters for selected time range.
• Tables for displaying alarm list history

This data is managed in reports, where data on production, alarms and work settings can be displayed in table or graphical formats (Pie charts or histograms). This data is selectable using filters to retrieve data by Time period, Batch number, or Production batch.

The data displayed in tables can be exported in Excel files using the command provided. In the section dedicated to reporting, the system calculates and displays performance efficiency indices according to the OEE standard. At the end of each shift, the system will automatically create an Excel file containing production line information and send it to the predefined recipients by email (this function can be enabled/disabled as desired). The flexibility of the system means that the “Target” OEE value can be customised, without modifying the project, to get coefficient calculations for each specific production requirement. All information or settings are subject to security management, as are user ‘Log-ons’.

Thanks to the statistical information provided by the system, the end user and builder are able to obtain all the information required to analyse production effectively. This process involves comparing real data with theoretical data to obtain crucial information to remove production bottlenecks and improve overall productivity. In addition, the machine downtime analysis function allows fast intervention, identification and analysis of the most frequent downtime causes, enabling the end user to optimise preventative maintenance to avoid the costs of lost production.

Remote Analysis via the Web
All statistical information gathered from the Movicon OEE system is available to authorised remote users: production line maintenance personnel, maintenance technicians or GIMA design engineers. Thanks to the Movicon Web Client, the supervisory system is accessible with any browser connecting remotely (internet, intranet). Web client users, assigned with authorised access passwords, can view any information they require in real-time, or the results of statistical analysis, by accessing from any point with a normal browser or mobile device (i.e. Smartphone).

The Movicon solution provided by GIMA not only meets all client requirements, but offers the added benefit of an unrestricted licence that allows users to purchase only what they need. This optimises the costs of the Movicon licence in relation to the size and number of plant production lines controlled.

“This latest flagship project for Movicon highlights, once again, the processing power of the system at a price that enables projects to be brought-in consistently under budget,” said Paul Hurst MD of P4A, the Movicon distributor in the UK. “Historically, SCADA systems have been more expensive in the UK than anywhere else; and with restricted licences, development costs and yearly system integrator fees, costs are getting out of hand. We are changing this situation with Movicon 11,” by offering all the functionality, scaleability, connectivity – and more – of existing SCADA systems, but at a price 30% to 50% less”

Photo Captions:

An example of a screen page provided for each machine in the system and these pages, when ‘clicked’, show all details and information relating to that production station.

One of the screens used in the Gima Spa production machine line supervision.

Alarm statistics (frequencies, durations) displayable both in table and graph format.

Thanks to the Movicon Web Client, the supervisory system is accessible with any browser connecting remotely.

The challenge required designing an auto-configurable system that was capable of connecting to machines independently of their type and configuration.

About P4A

Products4Automation (P4A) is a specialist supplier of new and innovative software and hardware solutions to the UK market. Products ranges available from P4A include the latest touch-screen HMI's and flat panel PCs, SCADA software and plug-ins, a wide range of SCADA enabled hardware, Alarm plug-in software for large automation systems, and a full range of Production Intelligence software solutions.

New IEEE Standard And Development Activities Designed To Aid Smart-Grid Communications And Distribution Automation

Empowering Consumer Choice and Boosting Power Reliability and Efficiency Dependent on More Robust Communications and Distribution-automation Capabilities

PISCATAWAY, N.J.--(BUSINESS WIRE)--IEEE, the world's largest professional association advancing technology for humanity, today announced the publication of a new standard, as well as the launch of three new standards-development activities, all designed to enhance the communications and distribution-automation capabilities of the smart grid globally.

“Many of the benefits that the world hopes to achieve through smart-grid development—such as empowering greater consumer choice in energy use, improving the reliability of power generation and distribution and more efficiently meeting skyrocketing power demand—are dependent on integrating significantly more robust systems for communications and distribution automation,” said Dr. W. Charlton Adams Jr., past president of the IEEE Standards Association (IEEE-SA). “The new standards activities approved by the IEEE-SA Standards Board are designed to enhance those very capabilities—and, in doing so, accelerate realization of the smart grid’s revolutionary promise.”

IEEE-SA has published IEEE 1591.1™-2012 – Standard for Testing and Performance of Hardware for Optical Ground Wire (OPGW). OPGW is being used in the smart grid to provide both grounding capabilities for transmission lines and communications back to utility systems such as Supervisory Control and Data Acquisition (SCADA). IEEE 1591.1 provides manufacturing, testing and procurement specifications for use with OPGW hardware. The new standard is available for purchase at the IEEE Standards Store.

Smart-grid standards projects newly approved by IEEE-SA include the following:

•IEEE P1909.1™ – Recommended Practice for Smart Grid Communication Equipment -Test methods and installation requirements – is intended to document testing and installation procedures that are geared specifically for communications equipment to be installed in various domains of the smart grid, such as generation, transmission and distribution. Safety, electromagnetic capability (EMC), environmental and mechanical tests are to be covered in the recommended practice, toward the goal of improving the safety and reliability of a wide range of smart-grid communications equipment.

read more: http://www.electricnet.com/doc.mvc/ieee-standard-and-development-activities-designed-to-aid-smart-grid-communications-0001

IT security lessons that Australia can teach us (2/2)

This fully-embedded firmware approach is fairly unique to SCADA-based operating systems, but helps one to understand that a highly controlled operating system and software environment – as mandated under the Australian DSD’s diktat - has a far lower risk of subversion than the free-for-all software approach see in the cost-cutting UK public sector.

Here at Avecto, whilst we understand the impetus behind moving to open source software that a growing number of UK government departments and allied public sector agencies are moving towards as part of their cost-cutting strategy, this does not mean that the Australian ideas enshrined in the DSD report cannot also be applied here in the UK.

This is because the principle on which our security offerings are built is Windows privilege management - namely the control over who has access to specific applications running on the corporate IT platform, as well as the underlying data.

This means, for example, that if the admin team only run their control and security software from within the network perimeter on known PCs, then access to those applications can be locked down to specific on-network computers.

Then, even if a set of admin account credentials are compromised by hackers, they cannot use those credentials from the Internet – they would still have to gain physical access to the terminals used by the admin staff.

read more: http://www.securitypark.co.uk/security_article267389.html

PROBLEMS WITH CURRENT GENERATION OF MES SYSTEMS BRING HIGH INVESTMENT RISK

Problems with Current Generation of MES Systems Bring High Investment Risk, says
Paul Hurst of Products4Automation

Current MES systems only represent a preliminary stage of development toward the
goal of intelligently controlled production processes, according to Paul Hurst of
P4A, the UK distributor for FELTEN Production Intelligence software. "MES systems
need to adopt a holistic and process-oriented approach," says Hurst. "This
represents an evolutionary advancement, one which releases production management
from its isolated self-image and associated performance limitations, enabling
significantly higher levels of production efficiency to be achieved."

For reasons of economic security, Hurst's recommendation for companies that are
still without MES systems, or solutions for machine and production data collection
(MDC/PDC), is to forego the use of classic systems. "Because the future clearly
belongs to PI-oriented solutions, a focus on outdated MES philosophies carries with
it a high investment risk," he says.

So what exactly are the problems with current generations of MES systems; and how
can these be overcome with a PI solutions approach? The problems fall into seven key
categories, according to Paul Hurst, they are: The role of humans is neglected; Too
isolated a perspective; A technical and system focus that is too strong; Rigid
instead of flexible process guidance; Extensively isolated planning and control
processes; Sufficient KPI control is not possible; No intrinsic administrative
optimisation methods are provided.

"Many automation strategies fail to consider that humans, as the keepers of
intelligence, know-how; or take account of the fact that experience with processes,
can never be completely replaced by technology," asserts Hurst. "Instead of
achieving a balance between technology and humans, MES systems have caused the
pendulum to swing predominantly towards automation and let the human factor, with
its potential to increase productivity, fade into the background.

In the field, production management is typically looked at in isolation, without
consideration of the environment and its specific conditions. MES systems have
actually reinforced this focus, because even with the requirement of integration
into ERP systems, these systems were not designed from a holistic perspective.

The actual potential for productivity increases lie within the processes, but
current MES strategies are dominated by a technical focus. And because a logical
process focus is missing, current optimisation possibilities can only be
insufficiently employed.

Read more: www.dmaeuropa.com  

DARPA releases formal solicitation for HACMS cyber security initiative for military vetronics

Computer scientists at the U.S. Defense Advanced Research Projects Agency (DARPA) in Arlington, Va., released a formal solicitation (DARPA-BAA-12-21) to industry Thursday for the agency's High-Assurance Cyber Military Systems (HACMS) program to safeguard civil and military embedded systems in vehicle electronics from hackers, computer viruses, and other cyber malware.
Earlier in the week, DARPA conducted its first industry briefings on the HACMS military cyber security program, which aims to develop a set of publicly available tools to help build embedded computing for high-assurance military vehicles with onboard networked military embedded systems that are able to resist efforts by hackers to attack and damage vetronics computers remotely while hiding the effects from monitors.
Although the HACMS program initially aims at embedded computing systems on military vehicles, DARPA officials say the tools and techniques the program develops may be applicable to other kinds of embedded systems, which in some circles are referred to as "cyber-physical" systems.
Improving cyber security for embedded systems is of the highest importance, DARPA officials say. In 2008, for example, there were about 30 embedded processors per person in developed countries, and in 2009, 98 percent of microprocessors were in embedded systems. Such systems range from large SCADA systems that manage physical infrastructure to medical devices such as pacemakers and insulin pumps, to computer peripherals such as printers and routers, to communication devices such as cell phones and radios, to vehicles such as airplanes and satellites.

Read more: http://www.militaryaerospace.com/articles/2012/02/darpa-releases-formal-solicitation-for-hacms-cyber-security-initiative-for-military-vetronics.html

SCADA Systems in Railways Vulnerable to Attack Government officials initially believed railway signal disruptions in December were tied to a cyber-attack against a Northwest rail company in December, Nextgov reported. But government and railway officials later denied that a U.S. railroad had actually been hit by a cyber-attack. "There was no targeted computer-based attack on a railroad," said Holly Arthur, a spokeswoman for the Association of American Railroads. While an attack has been ruled out, the incident highlights the dangers of industrial control systems controlling critical infrastructure. Train service on the unnamed railway was "slowed for a short while" and schedules delayed for 15 minutes on Dec. 1, according to a Transportation Security Administration memo obtained by Nextgov. A "second event" occurred just before rush hour the next day, but it did not affect schedules, according to the Dec. 20 memo, which summarized the agency's outreach efforts to share threat intelligence with the transportation sector. "Amtrak and the freight rails needed to have context regarding their information technical centers," the memo said, adding that rail operators were not focused on cyber-threats.

Anonymous publishes Israeli SCADA log-in details

member of the Anonymous hacktivist collective has published a list of Internet-facing Israeli SCADA (supervisory control and data acquisition) systems and alleged log-in details.
The user, who uses the Twitter handle of FuryOfAnon, posted the information on Pastebin with the message: "Who wanna have some fun with israeli scada systems?"
The pastebin post contains a list of IP-based URLs that allegedly correspond to Web administration interfaces of systems that are used to monitor automated equipment in industrial facilities.
Most of the URLs in the original post are no longer accessible. However, the hacker has since released a second list which contains newly found Israeli SCADA systems.
"Find their systems. Login using default logins ('100' being the password)" FuryOfAnon said. In December 2011, Google security engineer Billy Rios, disclosed that the default Web log-in credentials for the Siemens SIMATIC SCADA software are Administrator:100.
The same default log-in credentials might have been used by a hacker named pr0f to access a South Houston water utility's SCADA back in November 2011. The hacker claimed at the time that the system was protected by a three-character password.
FuryOfAnon's original Pastebin post also contains a list of email addresses and passwords belonging to people from the Israeli Ministry of Defense, Ministry of Foreign Affairs, Ministry of Health and the Israel Defense Forces (IDF). It's not clear if those also serve as log-in details for the listed SCADA systems.

Read more:
http://www.pcadvisor.co.uk/news/security/3329772/anonymous-publishes-israeli-scada-log-in-details/

SCADA industrial control systems exposed by security researchers

Proof-of-concept exploits for multiple vulnerabilities in SCADA products were demonstrated at the 2012 SCADA Security Scientific Symposium

Researchers showcased unpatched security flaws in software used to control critical industrial systems by oil, gas, water and electrical distribution plants at the 2012 SCADA Security Scientific Symposium (S4) last week.
The vulnerabilities ranged from information disclosure and privilege escalation bugs to remote denial-of-service (DoS) and arbitrary code execution flaws.
The research team, which included Reid Wightman, Dillon Beresford, Jacob Kitchel, Rubén Santamarta and two other researchers who chose to remain anonymous, worked as part of a project called Basecamp that was sponsored by industrial control systems (ICS) security firm Digital Bond.

The tested products were Control Microsystems' SCADAPack, the General Electric D20ME, the Koyo / Direct LOGIC H4-ES, Rockwell Automation's ControlLogix and MicroLogix, the Schneider Electric Modicon Quantum and Schweitzer's SEL-2032.
The affected vendors were not notified in advance about the discovered vulnerabilities and the proof-of-concept exploits showcased at S4 are being integrated into the popular Metasploit penetration testing framework.
"We are hoping that Project Basecamp will be a Firesheep moment for PLCs [programmable logic controllers]," said Reid Wightman, a Digital Bond security consultant and Basecamp project lead.
The Firesheep extension for Firefox, which can hijacking people's online accounts when they use open wireless networks, is credited with pushing major online service providers like Google, Facebook, Twitter and Hotmail to add support for persistent HTTPS connections.
Project Basecamp hopes to trigger a similar reaction from SCADA (supervisory control and data acquisition) software developers, whose products have largely been overlooked by the security research community until the Stuxnet industrial sabotage worm emerged in 2010.
Stuxnet, which is considered by many the most sophisticated malware of all times, exploited flaws in SCADA software from SIemens in order to inject malicious code in PLCs used to control uranium enrichment centrifuges at Iran's Natanz nuclear facility.
"For a long time this kind of software [SCADA] has been 'under the radar', living a quiet existence," said Rubén Santamarta, one of the Project Basecamp contributors. "But lately some researchers have been busy targeting ICS products and as a consequence dozens of vulnerabilities emerged in a relatively short time window."
"It has been a 'shock' for the industrial sector, I'm not sure whether they were really prepared to deal with that scenario," Santamarta said. "As a note, we should realise that probably their customers were not asking for security either."
Many of the security problems uncovered by Project Basecamp stem from design flaws and a lot of SCADA products have undocumented features that can be abused for malicious purposes.
"It's not rare to see an industrial software that uses hardcoded accounts or services that look almost like backdoors," said Luigi Auriemma, an independent security researcher who identified and reported SCADA vulnerabilities before. When these features are found, most of the time the only solution is to remove them, he said.