Since industrial control systems are usually integrated with numerous physical devices, the security of control systems plays an important role in safe operation of industrial chemical processes. However, due to the use of a large number of control actuators and measurement sensors and the increasing use of wireless communication, control systems are becoming increasingly vulnerable to cyber-attacks, which may spread rapidly and may cause severe industrial incidents. To mitigate the impact of cyber-attacks in chemical processes, this work integrates a neural network (NN)-based detection method and a Lyapunov-based model predictive controller for a class of nonlinear systems. A chemical process example is used to illustrate the application of the proposed NN-based detection and LMPC methods to handle cyber-attacks.

Recent cyberattacks against industrial control systems highlight the criticality of preventing future attacks from disrupting plants economically or, more critically, from impacting plant safety. This work develops a nonlinear systems framework for understanding cyberattack-resilience of process and control designs and indicates through an analysis of three control designs how control laws can be inspected for this property. A chemical process example illustrates that control approaches intended for cyberattack prevention which seem intuitive are not cyberattack-resilient unless they meet the requirements of a nonlinear systems description of this property.

One of the challenges for chemical processes today, from a safety and profit standpoint, is the potential that cyberattacks could be performed on components of process control systems. Safety issues could be catastrophic; however, because the nonlinear systems definition of a cyberattack has similarities to a nonlinear systems definition of faults, many processes have already been instrumented to handle various problematic input conditions. Also challenging is the question of how to design a system that is resilient to attacks attempting to impact the production volumes or profits of a company. In this work, we explore a process/equipment design framework for handling safety issues in the presence of cyberattacks (in the spirit of traditional HAZOP thinking), and present a method for bounding the profit/production loss which might be experienced by a plant under a cyberattack through the use of a sufficiently conservative operating strategy combined with the assumption that an attack detection method with characterizable time to detection is available.