The cybersecurity solution implemented by CONSYST focused on creating a secure and scalable OT infrastructure that aligned with Client’s cybersecurity standards. This involved segmenting the OT network into isolated zones, each with specific security measures tailored to its function, ensuring restricted communication between different areas. The system included a virtualized platform for critical applications and backup systems, providing high availability and disaster recovery capabilities. Firewalls were strategically deployed to protect the network perimeter and ensure secure communication between the OT and external systems.

A secure offline method for patch management and system updates was introduced, ensuring that updates were applied without compromising the air-gapped environment. To enhance operational visibility and security, an asset monitoring and anomaly detection system was integrated to provide real-time insights into network activity, identifying potential threats or vulnerabilities before they could impact operations. Backup systems were centralized for efficient management, and time synchronization across the network was ensured to maintain accuracy. Custom dashboards were developed to provide intuitive monitoring, allowing for easier asset management, real-time alerts, and improved audit readiness for the facility.

Our solution approach involved using a dedicated Data Acquisition Panel (DAQ) for each machine, with a focus on scalability. This plug-and-play model significantly reduced engineering efforts, implementation complexity, and fieldwork.

The existing machine panel was retrofitted with a few components that separated the signals from the field. All critical parameters from the existing machine controllers were fetched and new sensors/transducers were installed to collect additional data. Real-time monitoring and alerts through an audio-visual alarm system was installed to enable operator alerting.

CONSYST developed an IIoT solution to include continuous measurement and logging of milk levels and temperature in silos, with edge computing alerts to take preventive actions through a mobile application.

The data is securely stored in a central cloud hub, allowing retention even in the case of faulty local servers, and systematic synchronization between the cloud hub and the central server.

The central software and ERP work together to perform actions such as generating recommendations, issuing gate passes, and performing searches and queries, revolutionizing milk quality control process.

CONSYST integrated IIoT solutions with the IIoTNext Platform to implement advanced fly ash handling formula.
Real-time monitoring was enabled by integrating data from PLC and DCS systems into the cloud-hosted software. A DAQ system collected parameters from various units of the Ash Handling Plant and an IIoT gateway pushed data from different controllers and devices through various industrial communication protocols. Consolidated data from the IIoT Platform was integrated into the Management Software through REST APIs for real-time monitoring and control.

To meet the requirements of our client, our team leveraged our expertise in engineering and design to develop a state-ofthe-art controller for the turbine. We used AutoCAD to create detailed General Arrangement (GA) drawings, Bill of Materials (BOMs), wiring schematics, and other documentation necessary for the design and construction of the controller.

The controller is equipped with a Siemens S7-1500 Programmable Logic Controller (PLC) and a Unified Comfort Panel HMI for real-time monitoring and control. Our team developed the PLC program using TIA Portal, a powerful engineering software suite for industrial automation and control systems. This allowed us to create a control algorithm that maintains generator output while simultaneously adjusting the turbine Wicket gates and runner blades to optimize performance for any given water flow and head.

The controller we developed works seamlessly with any dual-regulated Kaplan turbine and includes key sections such as a startup procedure (both manual and automatic), various interlocks (hardwired and software-based), alarm management, and more. These features ensure that the controller operates safely and efficiently, minimizing downtime and maximizing performance.

Overall, our design and engineering services helped our client to modernize their control system with a cutting-edge product that improves efficiency and performance while adhering to the strictest safety and quality standards.