Multi-national gas supplier thwarts cyber attackers with ABB System 800xA v6 and ABB Security Update Service

Cyber threats drive needed change

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As the only supplier of natural gas to an entire country, updating aging control system hardware and software became critical after the WannaCry and Petya cyber attacks in 2017

End-of-life issues and aging equipment left this major gas supplier vulnerable to cyber attack.

After learning of the WannaCry and Petya cyber attacks in 2017, a large multi-national natural gas transportation and supply company with operations on three continents realized they needed to modernize their control systems’ cyber security defenses.

The first 800xA system running Windows XP to manage the compressor stations and the extended pipeline network was installed in 2006. Even though it was updated over the years, when Microsoft ended support for XP in early 2014, the company realized it was time to upgrade again. Losing XP support from Microsoft imperiled the efficiency of their control systems and exposed them to greater risk of cyber attack because the underlying operating system would no longer receive regular security updates.

Because so many people and businesses depend on the company for their energy needs, a cyber attack that interrupted operations could rise to the level of national security in at least one of the countries they operate. For that reason alone, avoiding unplanned downtime of this critical infrastructure – especially due to cyber attack – was critically important.

Main facts

Industry	Oil, Gas and Petrochemical
Customer	Oil and gas company
Location	Brazil
Solution	The ABB solution for the Floating Production Storage and Off-loading vessel (FPSO) and wellhead platforms distributes power for the entire production process, including the electric submersible pumps in the production wells below the seabed.
Benefits	ABB's service agreement with the company provides long-term maintenance support to ensure continuous process operation.

Challenge

Modernize control systems and improve control systems cyber defenses.

Solution

To solve this problem, ABB’s oil and gas industrial automation business unit (IAOG), upgraded the existing 800xA control system to the latest ABB Ability™ 800xA version 6. Specifically developed to support upgrades of older control systems running on unsupported operating systems, System 800xA v6 provides customers with a secure automation platform that lowers total cost of ownership while improving productivity.

Designed with cyber security in mind, System 800xA v6 provides a comprehensive set of embedded mechanisms to manage cyber security risks such as advanced access control, whitelisting, and remote monitoring and management of the control system’s security integrity. Operators and plant management can now access detailed information about installed system software, system health status, safety and security reports, field alerts and service contacts through myABB/My Control System, a secure web-based platform that supports System 800xA control systems.

To ensure the upgraded control system remained secure day-to-day, the client added a three year Automation Sentinel Maintenance Plus service agreement, which not only provides access to the latest control system software and enhancements, it better protects their control system from malware and cyber-attacks. Additionally, ABB’s Security Update Service automatically distributes ABB tested and validated updates directly to the customer site.

The Security Update Service eliminates the risk of introducing an errant patch that could crash a running control system. It also removes the need for control system operators to manually install and configure daily updates.

Results

Since the changeover to the new system, the customer has achieved higher productivity and improved performance through enhanced software functionality and system availability, leading to less unplanned downtime. Their systems run Microsoft’s latest patches and upgrades, and McAfee anti-virus signatures.

Now that plant personnel are no longer installing control systems upgrades and patches manually, the customer’s cyber security is greatly improved. ABB’s Security Update Service relieves them of this burden while ensuring their control system defenses are always up-to-date. This service saves maintenance staff hundreds of hours of manual work per year. Following the success of this pilot project, the company is now deploying the ABB Security Update Service to all their gas compressors.

Benefits

Enhanced security against cyber-attacks and cyber threats
Anti-virus and operating system software updated with ABB-approved patches
Minimal user effort evaluating, installing and testing patches
Increased time for maintenance staff to focus on core mission
Peace of mind knowing their systems are up-to-date
Lower total cost of ownership
Increased productivity through enhanced software functionality and improved system availability, performance and reliability
Improved cost predictability

800xA Electrical integration project

Collaborative services

During the original project delivery phase, protection relays were connected via Modbus which offered very limited diagnostic capability. Low-level diagnostics and non-sufficient data were not helping the company to efficiently operate and quickly troubleshoot the platform’s electrical system. Today’s IEC-connected protection relays offer much improved networking and diagnostic capabilities.

To improve integration between the electrification and automation systems, and also provide long-term operational support for the electrical equipment on the oil field ABB proposed a protection upgrade and 800xA integration project package. The project consisted of scoping, planning and assembling the Global Positioning System (GPS) switches, fiber optic networking, and modifications needed to achieve the objective of electrical time synchronization for the FPSO, and well head platforms. The project consisted of an electrical system upgrade with focus on the lifecycle of ABB protection relays and IEC618501 integration synchronized by the GPS.

ABB supplies medium voltage protection relays for modernization of the electric power system using IEC61850 protocol on the two fixed platforms and the FPSO. This modernization, which provides clock synchronization, enables fast identification of the root cause of any system failure.

To complete this project, a team of approximately 40 ABB electrical telecommunications and automation professionals were on board to execute the project. ABB faced two critical challenges: avoiding an extended maintenance shutdown, and not harming production while operating under a very tight timeframe. The task of these professionals was to integrate the relay to System 800xA, to ensure synchronization between the functioning of product and the progress of activities on the platform.

For all these requirements to be met, the team developed a comprehensive plan which suited all customer needs. The order was issued in early November 2015, and in February 2016, approximately 99 relays passed the factory acceptance test. The installation proceeded with flawless execution over a period of 10 days. At the end of the project, the ABB team was highly praised by the customer.

After the automation upgrade on the oil field was completed, ABB showed the real benefits of a high level of integration between electrification and automation systems, and how it could support company operators.

Upgrade project scope included:

GPS antennas in each well head platform and FPSO to have ABB System 800xA and electrical systems fully synchronized
IEC 800xA servers
Fiber optical and switches for IEC61850 network
Engineering services:
- Intelligent Electronic Device (IED) program conversion
- 800xA reconfiguration
- Hardware and software Factory Acceptance test at ABB facility

On-site services

IED mechanical installation
Fiber optical cable network and switches installation
Server installation
GPS antenna installation
Complete IED site test
Commissioning

Illustration of FPSO Peregrino

Collaborative services

ABB also provides automation and electrification support from a remote operation center in Brazil. Operating collaboratively, the two sites work on preventive maintenance and troubleshooting, with lower cost and faster customer response due to the remote nature of the service delivery. The work performed by ABB successfully contributes to more efficient production and cost savings at the two sites.

Remote monitoring and integrated operations are key. Authorized ABB personnel have remote access to the safety and automation systems on the FPSO thr ough remote monitoring and operations rooms. So, ABB can safely implement changes, tr oubleshoot, support and conduct remote health checks. The first analysis of any electrical failure can be done using the 800xA without entering electrical rooms, increasing safety for personnel.

ABB’s electrification solutions distribute electricity safely, reliably and efficiently throughout the production areas, ensuring fast, accurate data transfer from ABB’s electrical equipment to the automation system, while improving root cause analysis for the maintenance team. ABB also supplies the company’s onshore plant with electric drive systems that drive the gas compressors optimally at variable speed, thereby significantly reducing energy consumption and carbon dioxide emissions.

ABB personnel conduct system health checks

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