Process Control Systems

Today's process control systems are vulnerable to cyber attack. Security implications of 'modern' intertwined business and manufacturing systems need closer scrutiny.

The good old days of standalone process control systems –'unattached' from the rest of an enterprise's IT business systems – are long gone or going fast. The former situation made hacking these systems "difficult because the potential system intruder also had to physically enter the facility," reports Chemical Facility Security News. Not any longer. The integration of control systems with business IT systems has all but eliminated that protection.

Physical points of attack on control systems from outside of the physical protection of corporate or facility security are now everywhere, and a potential attack, especially on vulnerable processing operations, could come at any time. "The connection of the business systems to the internet has provided numerous gateways for purely electronic attacks on both the business IT and manufacturing control systems.” And with it, control system security has become virtually none existent especially at many high-risk chemical facilities.

Best-in-Class Process Control Systems:

• Offer SCADA (supervisory control and data acquisition) capability
• Provide methodology for measuring the control-flow of processes
• Security for combined business IT and manufacturing process integration

Top Considerations before Buying Process Control Systems:

Have a clear purchasing and evaluation plan. Process control systems are expensive and often replaced infrequently (maybe 10 to 15 years), as such careful planning as to the purchase and job criteria are primary considerations. A documented plan for identifying your needs should follow an eight-step process: 1. requirements development, 2. procurement process, 3. bidder selection process, 4. bidder evaluation process, 5. vendor award process, 6. configuration, 7. factory acceptance test, and finally, 8. start-up. 

Key Providers:

1. BinMaster, originally established in 1953 and now a division of Garner Industries, engages in the devevelopment, manufacturing, and supply of inventory management solutions, rotaries, capacitance probes, vibrating rods, ultrasonics, radar, pressure, tilt switches and the 3DLevel Scanner, which is a  dust-penetrating device that takes measurements at multiple points within a bin and calculates bin volume, works in even very large bins, and has the capability to visually map uneven material surfaces. Other products include flow detection and aeration devices for the feed and grain, food, plastics, pulp & paper, power, mining, and concrete industries. The company's solid-state point and continuous bin level indicator and control systems and sensoring devices are used while storing or processing powder and bulk solids such as cement & aggregates, chemicals, feed & grain, food, plastics, biofuels, pharmaceuticals, pulp & paper and wood products.

2. Automation Products, Inc., a private company established in 1960, develops, manufactures and markets the Dynatrol Systems of on-stream process analyzers, measurement and control instruments, level detectors, plus a line of new accessories. Dynatrol viscosity equipment is available for either in-line measurement or as a separate “stand alone” design for applications including liquid paints, primers and fluorescent coatings as well as the properties of other fluid products used in the manufacture of plastics and other polymers. The company's Dynatrol Density Cells are available in a wide variety of corrosion-resistant materials, and are complete when paired with one of our newest Digital or Analog output Converters. The Density Systems are available as well with the Red Goose Pipeline Product Sampling System.

3. AMETEK, Inc. operating in North America, Europe, Asia, and South America, was founded in 1930 and manufactures and sells electronic instruments and electromechanical devices. The company operates in two segments, Electronic Instruments Group and Electromechanical Group. 1. The Electronic Instruments Group segment offers instrumentation for various electronic applications used in transportation industries, including aircraft cockpit instruments and displays; airborne electronics systems; and pressure, temperature, flow, and liquid-level sensors for commercial airlines and aircraft and jet engine manufacturers. This segment also provides analytical instrumentation for the laboratory and research markets; instruments for food service equipment; measurement and monitoring instrumentation for various process industries; instruments and instrument panels for heavy trucks, heavy construction, and agricultural vehicles; and instrumentation and thermoplastic compounds for automotive, appliance, and telecommunications applications. 2. The Electromechanical Group segment produces brushless air-moving motors for aerospace, mass transit, medical equipment, computer, and business machine applications. It also offers specialty metal products, including steel and nickel clad alloys; stainless steel, cobalt, and nickel alloy powders; metal strip; specialty shaped and electronic wire; and metal matrix composites used in electronic thermal management. In addition, this segment supplies hermetically sealed (moisture-proof) connectors, terminals, and headers, as well as offers air-moving electric motors

4. Burkert Fluid Control Systems applies its measurement, control and regulation technology to engineering systems and solutions for water, steam, gases and other fluid media with products that include solenoid, process and analytical valves, pneumatic actuation, sensors and controllers. The company provides individual products as well as complete system and application solutions, from initial planning to after-sales support. Founded by Chriatian Burkert in 1946, Burkert is now in 35 countries. The company operates in the categories of industrial measurement, control and fluid technology. General product lines include fluid control systems; systems for measuring, controlling and regulating gasses and fluids from individual valves, sensors or controls up to complete automation solutions and fluid systems, as well as hygienic processing, steam, water treatment, cooling systems, gas handling, and microfluidics.

Process Control Systems
Definition: Process control system refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system.