FlexONet - Flexible Virtual Replication of OT Networks in the Energy Sector

How can substation functions in substations and local distribution stations be developed and tested in future in a hardware-independent manner? In the FlexONet project, Fraunhofer IOSB-AST, as the consortium leader, is developing a flexible test environment based on virtualised OT infrastructures for the energy supply sector.

Operational technology (OT) networks in the energy sector – for example, in substations, local distribution stations or specialised facilities – are becoming increasingly complex as the energy transition progresses.

New station functions, protection and automation components must be regularly tested, validated and integrated into existing infrastructure. To date, this has mainly been carried out on actual hardware, which is time-consuming, costly and severely limited in terms of the variety of configurations that can be tested.

At the same time, cybersecurity requirements are increasing: it must be possible to systematically analyse potential vulnerabilities and attack scenarios – ideally without jeopardising day-to-day operations.

The FlexONet collaborative project aims to virtually replicate OT infrastructures in the energy supply sector and make them available in a flexible, hardware-independent test environment. The aim is to enable test routines for substation components and functions to be carried out entirely within a virtualised environment in future – in a way that is reproducible, scalable and independent of specific manufacturers’ products. The project thus lays the foundation for a long-term vision: fully virtualised, hardware-independent substation functions in the energy supply sector.

As the consortium leader, Fraunhofer IOSB-AST is responsible for the overall scientific and technical coordination of the project. The main areas of focus for IOSB-AST include:

Process model for creating virtual infrastructure representations A key research contribution by the IOSB-AST is the development of a systematic process model that enables real OT infrastructures to be converted into virtual representations. This involves the structured analysis of existing information sources – including description files (e.g. SCL/SCD files in accordance with IEC 61850), network diagrams and process data – and their transformation into a consistent virtual model. The aim is a largely automated construction process that significantly reduces the manual modelling effort.

Setting up the flexible test environment The IOSB-AST designs and implements the central test environment in which the virtual infrastructures are instantiated, configured and operated. The environment is designed so that it:

• flexibly adaptable – various types of infrastructure and topologies can be implemented without any hardware changes,
• a range of test procedures – from traditional functional tests of individual components through to complex scenarios, and
• Security analyses – including the examination of attack scenarios and their impact on station operations.

Definition and implementation of use cases Together with the project partners, IOSB-AST has defined three key use cases, for each of which specific virtual infrastructures will be set up:

• Substations: Virtualisation of complex substation automation systems with protection, control and monitoring functions
• Local network substations: Illustration of decentralised substations in the distribution network with increasing levels of automation and sensor technology
• Specialised systems: Replication of specific infrastructures with individual requirements in terms of communication and functionality

All three use cases are fed by a network simulation, which provides realistic process data and thus creates an authentic operating environment within the virtual infrastructure.

Virtualised substation functions are developed and tested within the simulated infrastructures. In particular, the IOSB-AST is investigating how functions such as protection algorithms, automation logic and communication protocols can be reliably modelled and validated in a purely software-based environment.

FlexONet creates a vendor-neutral platform on which substation functions can be developed, tested and validated in a virtual environment. The results lay the foundations for a paradigm shift in energy supply operations: away from hardware-dependent test set-ups, towards flexible, virtualised test infrastructures that efficiently enable both functional tests and cyber security analyses.

This project is funded by the Federal Ministry for Economic Affairs and Climate Action.

• Technische Universität Dortmund
• H&S Hard- und Software Technologie GmbH & Co. KG
• Fachhochschule Bielefeld
• Stadtwerke Bielefeld GmbH
• Sprecher Automation GmbH