CAS KRUK-2000

2021: Integration with InfoWatch ARMA Industrial Firewall

On August 10, 2021, InfoWatch ARMA, which is part of GK InfoWatch, completed tests for compatibility of the next-generation industrial inter-network screen InfoWatch ARMA Industrial Firewall with automated process control systems based on the KRUG-2000 software and technical complex (CAS KRUG-2000) developed by NPF KRUG. The test confirmed the use of the ARMA Industrial Firewall InfoWatch as a means of information protection - a firewall with an intrusion detection and prevention system for APCS based on the KRUK-2000 CAS. More details here.

2018: Gazprom Neft Compliance Tests

The KRUG-2000 software and technical complex in January 2018 passed tests for compliance with the technical requirements of KRUG-2000 to Gazprom neft the automated facilities management systems oil processings at the Technopark site of the Company Avtomatika-Service(d.). Omsk

In the test report, the KRUK-2000 software and technical complex is classified as the basis for building reliable APCS: "confirmed capabilities of redundancy functions, as well as compliance with functional safety requirements according to SIL3 level, allow using KRUK-2000 CAS as DCS and PAZ systems for automation of hazardous production with continuous process management of Gazprom Neft PJSC enterprises."

From 1992 to January 2018. the NPF KRUK commissioned more than 700 APCS in various industries. The experience gained in the implementation of automation systems in the oil refining industry has led to the creation of a number of typical technical solutions.

2017

Compatibility with Kaspersky Industrial CyberSecurity

NPF Krug announced on November 20, 2017 that Kaspersky Lab's solution for critical infrastructures and industrial environments Kaspersky Industrial CyberSecurity was tested for compatibility with the KRUK-2000 software and technical complex (CAS KRUK-2000) and SCADA KRUK-2000 v4.2.

Kaspersky Industrial CyberSecurity is designed specifically to protect complex industrial environments, is highly flexible and adaptable to the needs of the enterprise. It is based on Kaspersky Lab's many years of expertise in the field of cybersecurity, a deep understanding of the nature of information systems vulnerabilities and close cooperation with international and Russian regulators in the field of protection requirements.

During the tests, a number of Kaspersky Industrial CyberSecurity components were tested, including the functions of software startup control and device connection, encryption protection, blocking access to network file resources from inaccurate nodes, as well as updating anti-virus databases and scanning selected areas. According to the results of testing, products can be used in a single information system, even taking into account the individual requirements of these solutions for the environment.

KRUK-2000 compatibility with Kaspersky Industrial CyberSecurity confirms the possibility of unimpeded information security of complex production infrastructures. Protecting enterprises from cyber threats is key - any vulnerabilities in technological software can lead to huge financial losses, and sometimes serious consequences for society. Tests have shown that the advanced technologies of Kaspersky Lab, created specifically to protect industrial facilities from malicious attacks, can be successfully used together with KRUK-2000, "commented Alexander Proshin, technical director of NPF Krug.

The possibility of integral use of Krug-2000 and Kaspersky Industrial software solutions CyberSecurity confirmed by the corresponding compatibility check act.

Version 8.1 of Real-Time System Simulator of Controller KRUK-2000 has been released

On May 16, 2017, the research and production company KRUG announced the release of version 8.1 of the Real Time Controller System (IOPRS).

IOPRS allows to execute arbitrary programs of Users and implements functions of object management, collection, storage and processing of information.

This release improves system reliability, facilitates configuration, and extends the applications of controllers under the control of the Real-Time Controller System.

For systems with increased reliability requirements, I/O module redundancy is implemented in a single controller. A mixed redundancy scheme will allow you to simultaneously use both 100% controller redundancy and 100% processor part redundancy.

Automatic mirroring of internal states and user program variables ensures transition when controller statuses are changed without the need to create additional user program code.

2015: KRUK-2000 Real-Time System Simulator

KRUK developed a new version of the Real-Time System Simulator of the KRUK-2000 Controller in the summer of 2015.

The IOPRS simulator is a software complex that implements all the basic functions of the Real-Time System of the KRUK-2000 Controller (IOPRS KRUK-2000), with the exception of the functions of polling I/O modules, as well as third-party devices using drivers. The IOPRS simulator completely repeats the processing algorithms of the controller's database variables, allows debugging the User's programs with imitation of input/output signals, intercontrolling with other simulators and controllers, transmitting data to SCADA KRUG-2000 ® using "internal" exchange protocols "PC-controller" and "TM-channel."

The product is designed to replace the controller during the development and debugging of user software of the automated control system (APCS) in the absence of the controller hardware and serves for:

• debugging programs written in the technology programming language KRUGOL
• verifying that the controller database is correct and that the "built-in" variable processing algorithms are configured correctly
• intercontroller interaction testing
• debugging the relationship between the controllers and the SCADA system
• training of employees of engineering companies
• creation of control object simulators.

2014: CAS KRUG-2000

CAS KRUK-2000 - software-technical complexes - are designed for measuring voltage, current, resistance, time, frequency, temperature, electric energy and power, indicators of electric energy quality.

CAS "KRUK-2000" can be used as part of automated information-measurement and control systems, including automated process control systems (APCS), telemechanics systems, commercial and technical accounting systems for electricity, control systems for electric power quality indicators in various industries with normal and fire/explosive production conditions.

PTK "KRUG-2000" is the multilevel hierarchical system of the distributed type consisting generally of the top and lower levels connected among themselves by means of cable (wire) digital communication lines on the basis of the standard IRPS, RS-232, RS-485, RS-422, CAN, Ethernet interfaces and (or) by means of wireless digital channels of communication on the basis of interfaces of radio modem connections, interfaces of cellular communication channels (GSM/GPRS), etc. (watch figure 1).

The lower layer is represented by microprocessor devices for collecting and processing information (hereinafter referred to as ODR), as which:

• TREI software control devices;
• measuring transducers Sh932;
• information, measurement and control systems DECONT;
• multifunctional controllers KR-500;
• Mercury Electric Energy Counters;
• counters of electric energy "SET-4TM.XX";
• meters of electrical energy quality indicators "RESOURCE-UF2";
• digital transmitters of PTs6806 type;
• communication servers (COM Servers) based on IBM PC compatible industrial computers.

The upper-level devices of the KRUK-2000 CAS are technical means of collecting and processing information made on the basis of IBM PC compatible industrial or office computers running WINDOWS operating systems, combined by a local computer network (via an Ethernet interface): operating and (or) archive database servers, local automated workstations (APS) and APS - clients, archive center, WEB-Control server, communication servers (COM-servers), engineering station, etc.

Generalized structural diagram of "KRUK-2000" CAS

In addition, other devices can be used as upper and lower level devices of the KRUK-2000 CAS, the type of which is approved and entered in the State Register of Measuring Instruments, the results of measurements and calculations of which are transmitted to the KRUK-2000 CAS through cable (wire) and wireless digital communication channels.

CAS Architecture

The CAS client-server architecture allows you to distribute computing tasks among subscribers of the system, thereby increasing the reliability and survivability of the complex.

For large APCS, consisting of several independent systems, it is possible to create a distributed database. The advantage of this approach is reduced requirements for server computing power, increased flexibility in terms of carrying out phased implementation of APCS, its repairability and localization of failures, making changes, etc. At the same time, client stations (operator stations) have real-time access to all local bases of the distributed system.

In most low-power systems, information exchange between database servers and controllers takes place on a single redundant network, and the DB servers themselves are combined with the operator stations, that is, simultaneously perform the functions of displaying, collecting and archiving information.

The distributed structure of the CAS and extended ranges according to the operating conditions of the I/O modules of the controllers provide the possibility of installing ODR in close proximity to the thermal power equipment. This approach makes it possible to significantly reduce the costs of cable products and installation works during the implementation of APCS.

Technical specifications

Information capacity

Number of input/output signals

• 1 controller from 1 to 2048
• for CAS as a whole up to 64000

Number of video frames (mnemonic diagrams) is not limited The number of dynamic elements per video frame (window) is limited only by screen size and PC performance Light/sound alarm types Number of standard alarm types 9 Number of messages (events):

• on the online DB server, pcs up to 21000
• on the archive database server, pcs.

Number of trends:

• there is no limit on the online database server
• on the archive database server is not limited

Frequency of trend update, ms

• on the online database server from 100
• on the archive database server from 100

Trend Depth

• online is determined by personal computer resources (RAM)
• archived Limited to computer hard disk capacity

Speed

Controller

• Interrogation time of discrete signals, μsec per 1 channel not more than 20
• Polling time of analog input signals, msec per 1 channel is not more than 1.5
• Displaying Information
  • Total frame change time, sec from 0.5
  • Operating information update cycle on the monitor, sec 0.25 to 1.0

• Restart Time
  • Total system restart time after power outage, from 30 to 60
  • Total controller restart time after power outage, from 20 to 30

• Transmission of control impacts
  • Total delay in information transmission via process protection channels, msec not more than 50

• Total delay of signals in control and interlocking circuits, ms not more than 100
• Delay in transmission of control commands by operator, ms not more than 200
• Event Logging
  • Duration of pre-crash and post-crash protocol registration, min. 5 to 20

• Period of variable registration in pre-emergency status protocols and trends, sec is determined by controller cycle time
• Minimum time interval for event recording, ms 10

Accuracy

• Limits of permissible basic reduced error of CAS measuring channels for standard electrical signals of current, voltage, resistance 0.05%
• Limits of permissible basic absolute error of temperature measurements using external resistance thermal transducers, normalized static characteristics of which are regulated by GOST 6651-2009 0.50 ° С
• Limits of the allowed main absolute error of measurements of temperature by means of external thermocouples which normalized static characteristics of transformation are regulated by GOST P 8.585 0.85 ºС
• Limits of permissible basic reduced error of output analog control signals of DC 0.1%
• Limits of permissible basic reduced error of signalling deviation of input analog signal from specified limits 0.05%

Limits of permissible basic reduced error of representation of input analog signals in the form of operational or historical trend, when their values are counted with the help of light indicator 0,05% Limits of permissible basic reduced error of value determination resulting from conversion of standard electrical signals of sensors according to regulated nonlinear dependencies and non-linearity tables, including:

• according to calibration tables of horizontal cylindrical tanks 0.12%
• by calibration tables of ball (spherical) tanks 0.15%
• according to interval nonlinearity tables regulated by MI 2153-2001 0.9%

Operating conditions

APCS CAS operating conditions in accordance with GOST 15150, CCL design, placement category 4.1

• Content of corrosive agents in the room atmosphere... 30 60% from values determined for type IV atmosphere
• Sulphur dioxide content 20... 250 mg/m3
• Chloride content 0.3... 30 mg/m3 (group of operating conditions of metals and alloys-1)
• Vibration in frequency range 10... 25 Hz with amplitude up to 0.1 mm
• Magnetic fields Constant and variable, with frequency 50 Hz, intensity up to 400 A/m (except controllers and computer equipment)
• Operating ambient temperature 10... 35 ° C, upper limit value for BAS - 40 ° C, lower limit value - 3 ° C, possible temperature change at a rate of 5 ° C/hour
• Relative humidity 50... 80%, upper value - 90%
• Atmospheric pressure 86.6... 106.7 kPa (650... 800 mm Hg), lower limit value 84 kPa (630 mm Hg)
• Dust content in the room Not more than 1.0 mg/m3 at particle size not more than 3 mm

CAS controllers are protected against the influence of:

• electronic interference
• electromagnetic fields with electric component not exceeding 0.3 V by 1m2
• pulse interference with amplitude up to 630 V and duration up to 2 μs.

Controller Operating Conditions

• Temperature 0... 60 ° С
• Special I/O Module Execution with Range
• - 60 ° С... 60 ° С
• Relative humidity 30... 85% at a temperature of 35 ° С
• Atmospheric pressure 84... 107 kPa
• Vibration 30... 500 Hz at acceleration up to 0.5 g

Power supply

1. The primary power source of APCS, including the means of information presentation (annunciators, secondary devices, indication lamps), is a three-phase AC network with voltage of 380/220 V with frequency of 50 Hz uninterrupted power supply.

2. Power supply of CAS devices

All CAS devices are powered by their own power sources (modules), which receive power from the general power grid.

Technical means remain operable:

• at changes of AC and DC network voltages by ± 25% with duration up to 100 ms
• for AC and DC power interruptions up to 20 ms.

The main principle of the power supply organization is the distribution of operating current among groups of consumers so that a separate fault or repair of the power supply element does not lead to a complete failure of the CAS. The current supply of the CAS devices, which implement the functions of technological protections, is carried out with the highest reliability either from the battery or from an AC source with redundancy from the battery.

Duplicated CAS devices are supplied from a redundant 220 V AC network, usually from different sources.

Uninterruptible power supply units made according to the On-line technology, having a booster device for connection to computers and allowing to monitor the condition of the CAS power supply system, are used for power supply of CAS devices. These units have built-in batteries and devices for balancing units.

Uninterruptible power supply system can be executed with double or triple redundancy.

The CAS provides the possibility to power cabinets with controllers from 24 V DC mains, from 220 V mains both AC and DC.

Reliability

APCS based on CAS KRUK-2000 refers to durable systems, the components of which are recoverable and serviced. CAS reliability is achieved by high quality of components (equipment of leading foreign and Russian companies), as well as redundancy of the most important parts of CAS.

The flexibility of the CAS allows you to reserve almost any of its components. CAS provides for "hot" redundancy:

• Operator stations
• Database Servers
• Information networks (network adapters, switches, cables)
• Controllers.

The controllers provide:

• 100% redundancy
• Redundancy of processor parts of controllers
• I/O module redundancy
• Individual I/O protection
• Data bus redundancy.

Values of reliability indicators of individual subsystems and functions

• MTBF of controllers used in the information subsystem for at least 75,000 hours
• Mean time between failures of controllers used in automatic control and emergency protection subsystems for at least 150,000 hours
• Average controller recovery time is not more than 15 - 20 minutes
• Average system recovery time does not exceed 1 hours
• Average service life of CAS as a whole not less than 10 years
• Service life of individual equipment (monitors, system units of operator stations, etc.) in accordance with operating instructions of these equipment

Openness

One of the characteristics of the KRUK-2000 CAS is openness, which means the possibility of simple, convenient, "seamless" communication - the compatibility of individual local automation systems of different manufacturers into a single integrated control system. The openness of CAS makes it possible to exchange information with adjacent and higher-level systems, and also minimizes the operational costs of supporting automation systems of various manufacturers (minimizing the total cost of ownership). Such capabilities are provided by the following CAS properties.

Information Openness

CAS allows the user (independent of the Supplier) to receive/transmit to any other system current (operational) parameter values with astronomical time marks, diagnostic data on CAS functioning; historical data in the form of parameter trends; online database settings, etc. Such capabilities are supported by international OPC DA/HDA, COM, DCOM, ODBC, etc., as well as common exchange protocols ModBus RTU, ModBus TCP, MEK60870-5-101, MEK60870-5-104. There are also options for exchanging with the user's file server and tools for converting data to Excel, Access, XML, and ASCII formats.

An API is provided to access the real-time database and archives. In addition, there is an extensive driver library for communicating with third-party devices for both the lower and upper level of CAS.

Configuration Openness This term refers to the ability of the User (independent of the Supplier) to make changes to the application software during its operation, namely, to perform all actions related to changing the configuration of the controller, system database, graphic design, application (technological) programs, as well as actions related to setting up the exchange of information with other systems. These tasks are solved in CAS in accordance with the requirements of the international standard for programming languages ​ ​ of controllers IEC-61131-3.

In addition, the User can create programs in the C++ language (for the controller) and high-level languages (for the upper-level stations). However, this requires coordination with the CAS Supplier, as it is related to the issue of ensuring guarantees for CAS and maintaining its temporary and reliable characteristics.

Classification openness

CAS KRUK-2000 supports a single, end-to-end mechanism for classifying and encoding objects within the enterprise (for example, AKS and KKS systems).

Network Openness (Protocol Layer)

Information exchange between CAS components and other systems is carried out with the support of international standards at the level of data exchange protocols, including: IP family protocols (TCP/IP, UDP, etc.), NTP, etc.

Network Openness (Physical Layer)

At the physical level, the following standards are supported in the KRUK-2000 CAS: 1. Ethernet technology is used for information exchange between CAS components and for information interaction with adjacent and upstream systems (ERP, MES, APCS, ACMS, etc.). The physical environment is copper, fiber. Execution - office or industrial, depending on the operating conditions. 2. RS-485 standard. 3. Field bus standards (FieldBus, Profibus, etc.).

Protect information from unauthorized access

In addition to organizational measures, the following mechanisms are included to ensure the protection of information from unauthorized access (NSD):

• software key (password) for access to work at the operator station and engineering station
• password for access to function group execution
• Password to access the individual function.

Common and system-wide software is delivered as executable modules and prevents them from being relayed to character format. KRUK-2000 CAS software is protected by a hardware key. Software of archiving tasks (including recording of emergency events and recording of CAS faults) together with organizational and technical measures eliminates the possibility of unauthorized erasure and recording of information in the corresponding data archives and arrays stored on disks.

Logging (form) of data archive, software and information software changes is provided.

In addition to organizational measures, the following mechanisms are proposed to ensure the protection of information from unauthorized access (NSD):

• Control sensors for cabinet opening with controllers
• Special controllers with electronic lock installed in cabinets (optional). Controllers are combined into an autonomous network, which goes to the workstation of the NSD protection service. The electronic keys (touch memory type) are individually programmed for each user.

Functions (tasks) performed by CAS

Information functions

• information collection, measurement and control of process parameters
• Event logging
• detection, recording and signalling of deviations of parameters from established boundaries
• manual data entry
• generation and output of data to operational personnel
• creation and printing of reporting documents
• archiving of parameters history on hard disk
• calculation tasks
• monitoring and recording of emergency protection actuation (interlocks and protections).

Control functions

• remote control of actuators (valves, pumps, fans, etc.)
• automatic regulation
• Software and Logic Management
• process protections and protective interlocks.

Auxiliary functions

• testing and self-diagnostics of CAS components
• validation of information signals
• check of control actions execution
• elimination of errors, failures, faults by connection of protection means and (or) interlocks of error signals and actions
• informing APCS engineer in case of technical devices failure with indication of device, place, time and type of failure
• recording errors, failures, faults and corrective actions
• Prohibition or authorization of information passing through measurement and alarm channels
• Detailed on-screen assistance to the operator
• time correction.

Controllers

Basic example of CAS implementation using the Russian-made TREI- 5B controller.

Controllers are compact multifunctional automatic control and control devices made in design 19 'of GOST R IEC 60297-3 standard or for installation on a standard DIN rack. The computer part of the controllers is made on a PC-compatible platform.

Controllers have a modular structure so that when the set and number of modules change, devices of various information and computing power can be configured. The controller architecture allows you to create systems with both a centralized and distributed structure. The module nomenclature includes intelligent I/O modules with the ability to execute a process program directly on the module itself, regardless of the central processor part.

Controllers provide:

• input of information from discrete signal sensors
• input of unified analog signals, thermocouple signals and resistance thermometers
• cyclic and address polling of sensors
• filtering and smoothing of parameter values; linearization of non-linearity of sensor characteristics: scaling (bringing to a physical scale) of parameter values; compensation of cold junctions temperature, extraction of square root
• control of violation of warning boundaries, emergency values, setpoints
• control of validity by boundary values, rate of change (or by other criteria)
• event recording (time stamp assignment) and generation of its characteristic
• reception of operator commands, emergency protection, generation of control commands for actuators
• generation of emergency protection commands by process parameters and operator actions
• formation of control actions for the implementation of regulatory laws (P-, I-, PID, etc.)
• control of actuators, monitoring of their condition.

Controllers have the following features:

• Certified and entered in the State Register of Measuring Instruments.
• Include network devices for inclusion in the local area network. The corresponding space-time characteristics of information exchange between controllers and upper-level devices are provided. Communication between controllers and the upper layer is digital, interference-resistant, protected from failures or destruction of equipment of the backup communication system.
• All process programming and controller configuration procedures can be executed via the interface channel.
• Static non-volatile RAM and FLASH memory are available to store working programs and current information.
• The controller is equipped with hardware and software self-diagnostics. Information on the operation of these means is generated by means of indicators located in the controller and messages transmitted to the subscriber through the interface channel.
• Controllers provide automatic restart (watchdog) when cyclic programs are stopped, as well as automatic restart (if necessary) after power recovery.
• MTBF is not less than 75 thousand hours. When using the 100% controller redundancy scheme, the system has a failure time of 150 thousand hours.

It is envisaged that it is possible to design increase the reliability of the controller by:

• Individual I/O redundancy in the controller
• redundancy of I/O modules within one controller
• redundancy of processor parts of the controller
• duplication of controllers.

Restoration of failed facilities at the place of their installation is carried out by replacing typical replacement elements (TEZ), which occurs, as a rule, without power outage. Replacement of TEZ, disconnection of some technical means for repair or prevention does not lead to malfunction of the entire CAS.

Technical specifications

• Number of discrete and analog I/O channels up to 2048
• Up to 255 I/O modules per ST-BUSM interface
• Pentium, AMD Geode LX PC104 + Processor Type (400 MHz )
• Non-volatile RAM (SRAM) MB 1
• 32 MB to 2 GB Flash Drive
• Standard PC/104-Plus interface up to 3 modules
• Built-in nonvolatile real-time clock Available
• Indication of inputs/outputs on each channel
• Communication links to external devices RS-232, RS-485, Ethernet, USB
• Structures 19 'standard GOST R IEC 60297-3,
• mounting on standard DIN rail
• Board sizes, mm 3U (100x160)
• 188x128x61
• The possibility of expanding with additional communication channels of various types is
• Operating ambient temperature range, ° С
  • typical
  • optional 0 to 60

• -60 to 60
• Rated supply voltage 220VAC/DC; 24VDC
• AC frequency 50 ± 1 Hz
• Supply voltage tolerances 95-264 EXPERT; 18-36 DC
• Explosion protection level and type [Ex ia] IIC
• Degree of protection of IP20 shell; IP65
• Analog input signals
  • unified DC signals: 0-5/± 5/0-20/4-20/± 20mA (GOST 26.011)
  • unified DC voltage signals: 0-5/0-10/± 5/± 10V
  • thermocouple signals of various gradations (GOST R 8.585)
  • signals of thermal resistance of TSM and TSP with nominal value of 50 and 100 Ohm (GOST 6651)

• Analog outputs
  • unified signals 0-20/4-20mA

• Discrete DC voltage inputs
  • logical zero from 0 to 6 V
  • logical unit from 18 to 30 V

• 220 V AC discrete output
  • There are

• Galvanic isolation
  • each analog and discrete input is isolated from other controller circuits

• withstand a sinusoidal voltage with an amplitude of up to 100 V and a pulse voltage with a duration of up to 50mks with an amplitude of up to 1500 V

Communication devices

In KRUK-2000, DevLink-C1000, a universal, freely programmable industrial controller, serves as controllers with low information power, as well as for collecting information from third-party devices and converting protocols.

DevLink-C1000 has the following capabilities:

• Polls many different devices (with support for reading archive data)
• Supports I/O module connections
• Allows easy creation of PID control loops (including cascade and multi-link)
• Support for archiving within the controller
• CAS includes deep integration with the upper level. ON