Search Results (552)

In this article, the development of the software system—a virtual simulator for FATEK programmable controllers for industrial processes—is proposed. The main purpose of the development is to create a virtual tool that emulates the operation of FATEK controllers, with the primary task being the receiving and sending of data related to the controller’s resources, using the FACON communication protocol. The simulator implements a protocol that is described in the FACON documentation. The simulator works as a slave device and returns a response only to a received request from the master device (this can be any program—SCADA or HM). The communication is asynchronous, i.e., receiving messages occurs independently of the operation of the simulator itself. The simulator is implemented as a desktop GUI application using the C++ programming language and the C++ Builder platform. This simulator can be used to manage tested SCADA and HMI programs for technological processes, etc. The main part of this work is the correct reading/writing of controller memory data (inputs/outputs/memory bits and registers). Through the developed simulator, you are fully tested under conditions of impossibility of using a real programmable controller. Full article

Wind turbine power curve modeling is essential for wind power forecasting, turbine performance monitoring, and predictive maintenance. However, SCADA data often contain anomalies (e.g., curtailment, sensor faults), degrading the accuracy of power curve predictions. This paper presents a parameter-transfer learning strategy within a preprocessing and modeling framework that jointly optimizes anomaly detection (iForest, LOF, DBSCAN) and WTPC regressors (MLP, RF, GP) via a multi-metric objective adaptable to specific modeling requirements. In the source domain, hyperparameters are explored with randomized search, and in the target domain, transferred settings are refined with Bayesian optimization. Applied to real SCADA from different locations and turbine models, the approach achieves a 90% reduction in optimization iterations and consistently improves target domain performance according to the objective, with no observed loss when comparable source and target turbines differ in site or rated power. Gains are larger for more similar source–target pairs. Overall, the approach yields a practical model-agnostic pipeline that accelerates preprocessing and modeling while preserving or improving fit, particularly for newly installed turbines with limited data. Full article

This study evaluates a solar-powered electric mobility pilot implemented at the University of Cuenca (Ecuador), combining two electric vans with daytime charging from a 35 kWp PV microgrid. Real-world monitoring with SCADA covered one year of operation, including efficiency tests across urban, highway, and mountainous routes. Over the monitored period, the fleet completed 5256 km in 1384 trips with an average occupancy of approximately 87%. Energy use averaged 0.17 kWh/km, totaling 893.52 kWh, of which about 98.2% came directly from on-site PV generation; only 2.41% of the annual PV output was required for vehicle charging. This avoided 1310.52 kg of CO₂ emissions compared to conventional vehicles. Operating costs were reduced by institutional electricity tariffs (0.065 USD/kWh) and the absence of additional PV investment, with estimated savings of around USD 2432 per vehicle annually. Practical guidance from the pilot includes aligning fleet schedules with peak solar generation, ensuring access to slow daytime charging points, maintaining high occupancy through route management, and using basic monitoring to verify performance. These results confirm the technical feasibility, economic competitiveness, and replicability of solar-electric transport in institutional settings with suitable solar resources and infrastructure. Full article

Advanced Persistent Threats (APT) are stealthy multi-step attacks, often executed over an extensive time period and tailored for a specific attack target. APTs represent a “low and slow” type of cyberattack, meaning that they most often remain undetected until the consequence of the attack becomes evident. Energy infrastructure, including power grids, oil and gas infrastructure, offshore wind installations, etc., form the basis of a modern digital nation. In addition to loss of power, financial systems, banking systems, digital national services, etc., become non-operational without electricity. Loss of power from an APT cyberattack could result in loss of life and the possibility of creating digital chaos. Digital payments becomes unavailable, digital identification is affected, and even POS terminals need to run on emergency power, which is limited in time, resulting in challenges in paying for food and beverages. Examples of Advanced Persistent Threats (APTs) targeting energy infrastructures include Triton, which in 2017 aimed to manipulate the safety systems of a petrochemical plant in Saudi Arabia, potentially leading to catastrophic physical consequences. Another significant incident is the Industroyer2 malware attack in 2022, which targeted a Ukrainian energy provider in an attempt to disrupt operations. The paper combines APT knowledge with energy infrastructure domain expertise, focusing on technical aspects while at the same time providing perspectives on societal consequences that could result from APTs. Full article

This paper investigates the utilization of artificial neural networks (ANNs) for the proactive identification of gearbox failures in wind turbines, boosting the use of operational SCADA data for predictive analysis. Avoiding gearbox failures, which can strongly impact the functioning of wind turbines, is crucial for ensuring high reliability and efficiency within wind farms. Early detection can be achieved though the development of a normal behavior model based on ANNs, which are trained with data from healthy conditions derived from selected SCADA variables that are closely associated with gearbox operations. The objective of this model is to forecast deviations in the gear bearing temperature, which serve as an early warning alert for potential failures. The research employs extensive SCADA data collected from January 2018 to February 2022 from a wind farm with multiple turbines. The study guarantees the robustness of the model through a thorough data cleaning process, normalization, and splitting into training, validation, and testing sets. The findings reveal that the model is able to effectively identify anomalies in gear bearing temperatures several months prior to failure, outperforming simple data processing methods, thereby offering a significant lead time for maintenance actions. This early detection capability is highlighted by a case study involving a gearbox failure in one of the turbines, where the proposed ANN model detected the issue months ahead of the actual failure. The present paper is an extended version of the work presented at the 5th International Conference of IFToMM ITALY 2024. Full article

Ensuring the reliable operation of wind turbines is critical for the global transition to sustainable energy, yet it is challenged by faults that are difficult to detect in real-time. Traditional diagnostics rely on centralized data, which raises significant privacy and scalability concerns. To address these limitations, this study introduces a Consensus-Regularized Federated Learning (CR-FL) framework. This framework mathematically formalizes and mitigates the problem of “client drift” caused by heterogeneous data from different turbines by augmenting the local training objective with a proximal regularization term. This forces models to learn generalizable fault features while preserving data privacy. To validate our framework, we implemented a lightweight neural network within a federated paradigm and benchmarked it against a powerful, centralized Light Gradient Boosting Machine (LightGBM) model using real-world SCADA data. The federated training process, through its inherent constraint on local updates, acts as a practical implementation of our consensus-regularization principle. Model performance was comprehensively evaluated using accuracy, precision, F1-score, and Area Under the ROC Curve (AUC) metrics. The results demonstrate that our federated approach not only preserves privacy but also achieves superior performance in key metrics, including AUC and precision. This confirms that the regularizing effect of the federated process enables the global model to generalize better across heterogeneous data distributions than its centralized counterpart. This study provides a practical, scalable, and methodologically superior solution for fault diagnosis in wind turbine systems, paving the way for more collaborative and secure infrastructure monitoring. Full article

The convergence of operational technology (OT) and information technology (IT) in industrial environments, such as water treatment plants, has significantly increased the attack surface of Supervisory Control and Data Acquisition (SCADA) systems. Traditional intrusion detection systems (IDS), which focus solely on network traffic, often fail to detect stealthy, process-level attacks. This paper proposes a Digital Twin-driven Intrusion Detection (DT-ID) framework that integrates high-fidelity process simulation, real-time sensor modeling, adversarial attack injection, and hybrid anomaly detection using both physical residuals and machine learning. We evaluate the DT-ID framework using a simulated water treatment plant environment, testing against false data injection (FDI), denial-of-service (DoS), and command injection attacks. The system achieves a detection F1-score of 96.3%, a false positive rate below 2.5%, and an average detection latency under 500 ms, demonstrating substantial improvement over conventional rule-based and physics-only IDS in identifying stealthy anomalies. Our findings highlight the potential of cyber-physical digital twins to enhance SCADA security in critical infrastructure. In the following sections, we present the motivation and approach underlying this framework. Full article

Monitoring the health of wind turbine foundations is essential for ensuring their operational safety. This paper presents a cost-effective approach to obtain rotational stiffness of wind turbine foundations by using only acceleration and wind speed data that are part of SCADA data, thus lowering the use of moment and tilt sensors that are currently being used for obtaining foundation stiffness. First, a convolutional neural network model is applied to map acceleration and wind speed data within a moving window to corresponding moment and tilt values. Rotational stiffness of the foundation is then estimated by fitting a line in the moment-tilt plane. The results obtained indicate that such a mapping model can provide stiffness values that are within 7% of ground truth stiffness values on average. Second, the developed mapping model is re-trained by using synthetic acceleration and wind speed data that are generated by an autoencoder generative AI network. The results obtained indicate that although the exact amount of stiffness drop cannot be determined, the drops themselves can be detected. This mapping model can be used not only to lower the cost associated with obtaining foundation rotational stiffness but also to sound an alarm when a foundation starts deteriorating. Full article

Simulations are conducted using a microscale model framework to quantify differences in projected Annual Energy Production (AEP), Capacity Factor (CF) and wake losses for large offshore wind farms that arise due to different input datasets, installed capacity density (ICD) and/or wake parameterizations. Differences in CF (and AEP) and wake losses that arise due to the selection of the wake parameterization have the same magnitude as varying the ICD within the likely range of 2–9 MW km⁻². CF simulated with most wake parameterizations have a near-linear relationship with ICD in this range, and the slope of the dependency on ICD is similar to that in mesoscale simulations with the Weather Research and Forecasting (WRF) model. Microscale simulations show that remotely generated wakes can double AEP losses in individual lease areas (LA) within a large LA cluster. Finally, simulations with the Coupled Ocean-Atmosphere-Wave-Sediment Transport (COAWST) model are shown to differ in terms of wake-induced AEP reduction from those with the WRF model by up to 5%, but this difference is smaller than differences in CF caused by the wind farm parameterization used in the mesoscale modeling. Enhanced evaluation of mesoscale and microscale wake parameterizations against observations of climatological representative AEP and time-varying power production from wind farm Supervisory Control and Data Acquisition (SCADA) data remains critical to improving the accuracy of predictive AEP modeling for large offshore wind farms. Full article

Amid the global shift toward clean energy, wind power has emerged as a critical pillar of the modern energy matrix. To improve the reliability and maintainability of wind farms, this work proposes a novel hybrid fault detection approach that combines expert-driven diagnostic knowledge with data-driven modeling. The framework integrates autoencoder-based neural networks with Failure Mode and Symptoms Analysis, leveraging the strengths of both methodologies to enhance anomaly detection, feature selection, and fault localization. The methodology comprises five main stages: (i) the identification of failure modes and their observable symptoms using FMSA, (ii) the acquisition and preprocessing of SCADA monitoring data, (iii) the development of dedicated autoencoder models trained exclusively on healthy operational data, (iv) the implementation of an anomaly detection strategy based on the reconstruction error and a persistence-based rule to reduce false positives, and (v) evaluation using performance metrics. The approach adopts a fault-specific modeling strategy, in which each turbine and failure mode is associated with a customized autoencoder. The methodology was first validated using OpenFAST 3.5 simulated data with induced faults comprising normal conditions and a 1% mass imbalance fault on a blade, enabling the verification of its effectiveness under controlled conditions. Subsequently, the methodology was applied to a real-world SCADA data case study from wind turbines operated by EDP, employing historical operational data from turbines, including thermal measurements and operational variables such as wind speed and generated power. The proposed system achieved 99% classification accuracy on simulated data detect anomalies up to 60 days before reported failures in real operational conditions, successfully identifying degradations in components such as the transformer, gearbox, generator, and hydraulic group. The integration of FMSA improves feature selection and fault localization, enhancing both the interpretability and precision of the detection system. This hybrid approach demonstrates the potential to support predictive maintenance in complex industrial environments. Full article

Cyber-physical systems such as Supervisory Control and Data Acquisition (SCADA) have been applied in industrial automation and infrastructure management for decades. They are hybrid tools for administration, monitoring, and continuous control of real physical systems through their computational representation. SCADA systems have evolved along with computing technology, from their beginnings with low-performance computers, monochrome monitors and communication networks with a range of a few hundred meters, to high-performance systems with advanced 3D graphics and wired and wireless computer networks. This article presents a methodology for the design of a SCADA system with a 3D Visualization for Drinking Water Supply, and its implementation in the Lerma Basin System of Mexico City as a case study. The monitoring of water consumption from the wells is presented, as well as the pressure levels throughout the system. The 3D visualization is generated from the GIS information and the communication is carried out using a hybrid radio frequency transmission system, satellite, and telephone network. The pumps that extract water from each well are teleoperated and monitored in real time. The developed system can be scaled to generate a simulator of water behavior of the Lerma Basin System and perform contingency planning. Full article

Wind farm performance monitoring has traditionally relied on deterministic models, such as power curves or machine learning approaches, which often fail to account for farm-wide behavior and the uncertainty quantification necessary for the reliable detection of underperformance. To overcome these limitations, we propose a probabilistic methodology for turbine-level active power prediction and uncertainty estimation using high-frequency SCADA data and farm-wide autoregressive information. The method leverages a Stochastic Variational Gaussian Process with a Linear Model of Coregionalization, incorporating physical models like manufacturer power curves as mean functions and enabling flexible modeling of active power and its associated variance. The approach was validated on a wind farm in the Belgian North Sea comprising over 40 turbines, using only 15 days of data for training. The results demonstrate that the proposed method improves predictive accuracy over the manufacturer’s power curve, achieving a reduction in error measurements of around 1%. Improvements of around 5% were seen in dominant wind directions (200°–300°) using 2 and 3 Latent GPs, with similar improvements observed on the test set. The model also successfully reconstructs wake effects, with Energy Ratio estimates closely matching SCADA-derived values, and provides meaningful uncertainty estimates and posterior turbine correlations. These results demonstrate that the methodology enables interpretable, data-efficient, and uncertainty-aware turbine-level power predictions, suitable for advanced wind farm monitoring and control applications, enabling a more sensitive underperformance detection. Full article

This paper gives a thorough overview of the technological advancements in microgrid systems, focusing on the Internet of Things (IoT), predictive analytics, real-time monitoring, architectures, control strategies, benefits, and drawbacks. It highlights their importance in boosting system security, guaranteeing real-time control, and increasing energy efficiency. Accordingly, researchers have embraced the involvement of many control capacities through voltage and frequency stability, optimal power sharing, and system optimization in response to the progressively complex and expanding power systems in recent years. Advanced control techniques have garnered significant interest among these management strategies because of their high accuracy and efficiency, flexibility and adaptability, scalability, and real-time predictive skills to manage non-linear systems. This study provides insight into various facets of microgrids (MGs), literature review, and research gaps, particularly concerning their control layers. Additionally, the study discusses new developments like Supervisory Control and Data Acquisition (SCADA), blockchain-based cybersecurity, smart monitoring systems, and AI-driven control for MGs optimization. The study concludes with recommendations for future research, emphasizing the necessity of stronger control systems, cutting-edge storage systems, and improved cybersecurity to guarantee that MGs continue to be essential to the shift to a decentralized, low-carbon energy future. Full article

Gearbox failures are a major cause of unplanned downtime and increased maintenance costs, making accurate diagnosis crucial in ensuring wind turbine reliability and cost-efficiency. However, most existing diagnostic methods fail to fully extract the spatiotemporal features in SCADA data and neglect the impact of class imbalance, thereby limiting diagnostic accuracy. To address these challenges, this paper proposes a fault diagnosis model for wind turbine gearboxes based on CNN-SA-GRU and Focal Loss. Specifically, a CNN-SA-GRU network is constructed to extract both spatial and temporal features, in which CNN is employed to extract local spatial features from SCADA data, Shuffle Attention is integrated to efficiently fuse channel and spatial information and enhance spatial representation, and GRU is utilized to capture long-term spatiotemporal dependencies. To mitigate the adverse effects of class imbalance, the conventional cross-entropy loss is replaced with Focal Loss, which assigns higher weights to hard-to-classify fault samples. Finally, the model is validated using real wind farm data. The results show that, compared with the cross-entropy loss, using Focal Loss improves the accuracy and F1 score by an average of 0.24% and 1.03%, respectively. Furthermore, the proposed model outperforms other baseline models with average gains of 0.703% in accuracy and 4.65% in F1 score. Full article

Gearbox failure represents one of the most time-consuming maintenance challenges in wind turbine operations. Abnormal temperature variations in the gearbox high-speed shaft (GHSS) serve as reliable indicators of potential faults. This study proposes a Spatio-Temporal Attentive (STA) synergistic architecture for GHSS fault detection and early warning by utilizing the in situ monitoring data from a wind farm. This comprehensive architecture involves five modules: data preprocessing, multi-dimensional spatial feature extraction, temporal dependency modeling, global relationship learning, and hyperparameter optimization. It was achieved by using real-time monitoring data to predict the GHSS temperature in 10 min, with an accuracy of 1 °C. Compared to the long short-term memory (LSTM) and convolutional neural network and LSTM hybrid models, the STA architecture reduces the root mean square error of the prediction by approximately 37% and 13%, respectively. Furthermore, the architecture establishes a normal operating condition model and provides benchmark eigenvalues for subsequent fault warnings. The model was validated to issue early warnings up to seven hours before the fault alert is triggered by the supervisory control and data acquisition system of the wind turbine. By offering reliable, cost-effective prognostics without additional hardware, this approach significantly improves wind turbine health management and fault prevention. Full article