2025 AIChE Annual Meeting

(243d) A Data-Driven Transformer-Based Framework for Cyber-Process Incident Detection and State Reconstruction in Highly Integrated Process Systems

Authors

Amirsalar Bagheri - Presenter, Kansas State University
Amirmohammad Ebrahimi, Kansas State University
Davood Pourkargar, Kansas State University
Cyber-physical systems (CPS) in the process industries commonly use advanced control architectures such as model predictive control (MPC). These frameworks rely on accurate real-time measurements and state estimation for optimal performance [1,2]. However, the growing reliance on networked sensors and actuators exposes such systems to adversarial cyber-attacks, particularly those that compromise sensor readings. For example, falsified temperature readings can lead to erroneous thermal and composition state estimates, which misleads the MPC and results in incorrect control actions affecting multiple process variables. The tight feedback interconnection between estimation and control can propagate corrupted data throughout the system, destabilizing operations and potentially causing safety-critical failures or significant economic losses.

To improve cyber-resilience in CPS, recent efforts have focused on machine learning (ML)-based approaches for attack detection and state reconstruction [3-5]. Methods employing feedforward neural networks (FNNs), recurrent neural networks (RNNs), and Lyapunov-based MPC formulations have shown promise in detecting cyber-attacks and restoring corrupted measurements for system stabilization [6-8]. However, the effectiveness of these techniques can be limited in integrated process systems, where the complexity of inter-unit dependencies and recycles increases the difficulty of isolating and mitigating attacks. Highly integrated chemical processes involve complex interactions among unit operations, shared sensing infrastructures, and tightly coupled control loops [9,10]. In such environments, a localized cyber-attack on a single sensor can cascade through the network, affecting multiple downstream units and amplifying disruption. Traditional anomaly detection methods often fail in these settings due to their limited ability to model the dynamic interdependencies across subsystems.

This work presents a data-driven, transformer-based framework for detecting and identifying cyber-attacks in highly integrated process systems, focusing on the benzene alkylation benchmark process. The system includes five temperature sensors, which may be subjected to singular or simultaneous attacks. Two complementary approaches are proposed for cyber-incident detection and sensor compromise identification. The first approach employs a centralized self-attention transformer that processes sequences of historical sensor measurements to capture temporal patterns indicative of cyber-attacks [11]. This model performs joint detection and identification using a multi-label classification strategy, enabling both the detection of an attack event and the localization of compromised sensors. However, this joint task suffers from performance degradation due to class imbalance, particularly in scenarios involving multi-sensor attacks, which are relatively rare in the training data compared to single-sensor or no-attack instances.

To address this challenge, we propose a two-tier detection-identification architecture. The first tier uses an FNN trained as a binary classifier to detect the presence of an attack. Upon detection, the second tier—a self-attention transformer—identifies the compromised sensors through a multi-label classification task explicitly trained on imbalanced datasets. This separation enhances detection accuracy and mitigates the effects of class imbalance in sensor identification. Both approaches are integrated with an Extended Kalman Filter (EKF) for post-attack state reconstruction. By incorporating the outputs of the ML-based detection and identification modules with EFK-based estimation, the proposed method enables the recovery of reliable internal states even in the presence of compromised measurements, further enhancing the control system’s resilience and stability.

References:

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