Flow-Conducting Equipment Control for Cyber-Induced Cavitation
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Solution Overview
Problem
Flow-conducting devices in industrial installations, such as centrifugal pumps, are vulnerable to cavitation damage caused by cyber attacks, leading to potential production downtimes and safety risks due to the manipulation of operating conditions that create vapor bubbles and subsequent implosion, causing mechanical stress and damage.
Innovation Solution
A method and unit that utilize sensors to detect anomalies in operating states, such as pressure fluctuations and vibrations, to identify and respond to cyber attacks by adjusting setpoint variables and actuating components to prevent cavitation, including disconnecting the flow-conducting device from the network to prevent further attacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flow-conducting devices are connected to industrial networks for automation and monitoring, then productivity and control capability are improved, but vulnerability to cyber attacks increases
Solution Approach 1:
The patent introduces a protective intermediary system that monitors operating parameters (pressure, temperature, flow rate) and detects cyber-induced anomalies. This intermediary layer separates the control system from direct network exposure, allowing automated monitoring while filtering out malicious commands that would cause cavitation conditions.
Solution Approach 2:
The system implements continuous feedback loops that monitor operating parameters and compare them against expected ranges. When cyber attacks attempt to create cavitation conditions, the feedback mechanism detects the abnormal parameter changes and triggers protective responses, maintaining productivity while preventing damage.
2Reliability
If operating parameters are monitored and adjusted to prevent cavitation, then device reliability is improved, but system complexity increases
Solution Approach 1:
The monitoring system performs multiple functions simultaneously: it monitors for cavitation conditions, detects cyber attack patterns, and adjusts operating parameters. By consolidating these functions into a single integrated system rather than separate dedicated systems, the patent improves reliability without proportionally increasing complexity.
Solution Approach 2:
The system prevents cavitation by dynamically adjusting operating parameters (pressure, flow rate, temperature) based on real-time monitoring. Rather than adding complex physical protection mechanisms, the solution changes operational parameters to stay within safe ranges, achieving reliability through software-based parameter management.
3Reliability
If setpoint variables are adjusted in response to detected attacks, then protection effectiveness is improved, but response time is reduced
Solution Approach 1:
The system pre-establishes safe operating ranges and response protocols before cyber attacks occur. When anomalies are detected, pre-programmed responses are immediately executed without requiring complex real-time decision-making. This preliminary preparation enables fast response while maintaining effective protection.
Solution Approach 2:
Upon detecting cyber-induced cavitation conditions, the system rapidly adjusts setpoint variables to return to safe operating parameters, skipping intermediate analysis steps. This urgent correction prioritizes speed of response to prevent damage, accepting temporary operational disruption to restore safety quickly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively prevents cyber-induced cavitation damage by identifying and mitigating irregular operating modes, reducing the risk of downtime and ensuring the integrity of flow-conducting devices, even in cases where the process control system is compromised, while maintaining low implementation costs.
Implementation Method 1
Cavitation is understood to mean the forming and dissolving of vapor-filled cavities (vapor bubbles) in a medium. When cavitation occurs two borderline cases are differentiated... In the case of vapor cavitation (also referred to as hard cavitation), the cavities mainly contain vapor of the surrounding fluid. Such cavities collapse under the effect of the external pressure by bubble implosion.
Implementation Method 2
Centrifugal pumps are based on a functional principle of transmission of energy to a fluid by changing swirling owing to a torque which is applied by a rotating impeller wheel to the fluid flowing through the latter. A centrifugal pump is a continuous-flow machine. It utilizes the centrifugal force to deliver fluid.
Data Source
AI summary
A method and device for protecting a flow-conducting device of an installation against cavitation initiated by cyber attacks. At least one signal relating to an operating state of the installation is evaluated by an evaluation unit in order to detect a cyber attack by comparison with at least one reference value. If the evaluation unit detects a willfully brought-about irregular operating mode of the installation based on the evaluation, the unit passes on signals to components of the installation to bring about an installation operating mode which is in compliance with regulations and during which generation of cavitation is avoided, and produces a state in which the flow-conducting device is protected against the current cyber attack and/or against future cyber attacks.