ICSUnitSim on ESP32 board ("ICS on Chip")

Realtime Process Simulation of Plant Water Supply Unit

Simulation Generates logically correct Modbus signals of Water Supply facility using ESP32 MCU board with ModbusTCP interface

Simulation intended for HMI and DCS testing with realtime values and for ICS security research

Developed using Arduino IDE for ESP32 (ESP 32 MCU board is available on Aliexpress for approx price of 5$)

Version history

Added HMI project backup for output visualisation
V0.2 Introduced Pump AUTO functionality, adjustable setpoints, tank_drain variable on modbus
V0.1 Initial code with manual controls only

HMI Example
Simulation setup
Virtual process P&ID
Modbus addressing
Follow
Credits
Version history

HMI Visualisation Example

HMI_Project folder contains latest backup of Ignition HMI Project, restore it to you Ignition setup for below result.

Current HMI Example is designed on Ignition SCADA by Inductive Automation

Free trial versions of HMI software like RapidSCADA, Ignition and Advantech is available on internet.

For simple Modbus values reading/writing you could use RMMS tool http://en.radzio.dxp.pl/modbus-master-simulator/

Simulation Setup

Virtual process's P&ID

Modbus addressing

!Important!: Modbus library uses 0 based adressing

Modbus Coils Offsets (read\write)

mot_start, address: 100, boolean, Start button, 1 to activate, returns to 0 after activation

mot_stop, address: 110, boolean, Stop button, 1 to activate, returns to 0 after activation

valve_state, address: 120, boolean 0-Closed 1-Open (Controlled by start/stop logic)

mat_auto, address:130, boolean, 1-Pump automatic mode(by setpoints), 0 - manual mode

Modbus input status (Discrete Inputs) Offsets(read only)

mot_run, address: 100, boolean, 1 running, 0 stop
mot_trip, address: 110, boolean, Motor trip state, cause: Tank full, Valve closed, Random trip (1 of 10000)

Modbus Input Register Offsets (read only)

mot_load, address: 100; Uint16, range:0-100, random motor load simulation

flowm_flow, address: 110, Uint16, range:0-10, flow value depending on mot_load 

tank_level, address: 120, Uint16, range:0-65000, 65000 value trips the motor, has constant (random of 4) drainage flow

tank_drain,  address: 130; Uint16, Random drain by process

Modbus Holding Register Offsets (read\write)

tank_Hi, address: 100; Uint16, adjustable Hi level setpoint, for turning motor OFF in AUTO mode

tank_Lo, address: 110; Uint16, adjustable Lo level setpoint, for turning motor ON in AUTO mode

Follow

Follow author on twitter for project updates https://twitter.com/supeyev/

Credits

Based on Alexander Emelianov (a.m.emelianov@gmail.com) Modbus library https://github.com/emelianov/modbus-esp8266 @emelianov
Inductive Automation's Ignition SCADA used for HMI Design https://inductiveautomation.com/ignition/

nielsolie / ICSUnitSim