To meet the UK’s net-zero target by 2050, utilities must modernise their infrastructure with smart technologies—an evolution that can increase cyberattack risk with serious economic and social consequences. The 36-month DEFGRID project, funded by UKRI’s Industrial Strategy Challenge Fund, aims to build a secure industrial IoT demonstrator for the utility sector using Digital Security by Design (DSbD) technologies, specifically the Morello Board, developed by arm in collaboration with the University of Cambridge and partners.
By testing open-source software at PNDC and SGN sites, the project is evaluating how DSbD hardware can reduce cyber risk and enhance security across critical infrastructure, including electricity, gas, and water.
Project Background
The increasing digitalisation of critical infrastructure, particularly within the power utility sector, presents significant cybersecurity challenges. Legacy communication protocols, while widely deployed, often lack robust security mechanisms, making them vulnerable to cyberattacks. The DEFGRID project addressed these challenges by demonstrating the application of Digital Security by Design (DSbD) principles using the Morello Board, a hardware-based security platform. The Modbus-based power networks application case study focuses on integrating the Morello Board into a real-world power network scenario using Modbus TCP, a prevalent legacy protocol in utility applications, to enhance security and resilience.
Digital Security by Design (DSbD) represents a fundamental shift in cybersecurity, embedding security directly into hardware and software. The Morello Board, a CHERI-based (Capability Hardware Enhanced RISC Instructions) research platform, represents DSbD by implementing fine-grained memory protection, effectively preventing common memory-related vulnerabilities like buffer overflows and leaks. This is particularly crucial for critical infrastructure like power networks, where increasing digitalisation introduces new cyberattack risks. The Morello Board’s enhanced memory safety offers a promising solution for securing power network devices, significantly reducing the potential for disruptive cyberattacks and ensuring reliable and safe grid operations.
Challenges of Grid Digitalisation
The digitalisation of power grids presents several key challenges. The increased processing needs of digital substations require a variety of hardware components with high processing capabilities to ensure reliable and efficient operation. The transition to a fully digital grid will be a long process, necessitating the coexistence of legacy and new devices for decades, creating integration complexities.
The critical nature of power grids makes them prime targets for cyberattacks, necessitating robust security measures. Legacy system integrations, along with data management, supply chain risks, interoperability, and regulatory compliance, are key challenges for digitalisation in the OT power grid.
The Role of Digital Substations and IEDs
Digital substations are a key component of the future power grid. They rely on Intelligent Electronic Devices (IEDs) with high processing capabilities to perform advanced protection, control, monitoring, and cybersecurity functions. Each substation has multiple feeder bays, and each bay requires various IEDs, including protection relays, communication devices, and phasor measurement units (PMUs).
High-Performance Computing Needs
Virtualisation of substation control functions necessitates high-performance servers with powerful processors and ample memory for efficient and reliable operation. This combination of physical and virtual components offers flexibility and efficiency.
Security Concerns
Securing the critical power network and ensuring the safety of grid operations are paramount. The estimated number of digital devices needed in the UK power grid reaches tens of millions. Robust security measures are vital to protect these devices and mitigate the risks of cyberattacks.
Flexibility Services and their Impact
Flexibility services, such as demand response and energy storage, require real-time monitoring, optimisation algorithms, and advanced data analytics. These services rely on millions of digital devices, including smart meters, energy storage systems, and communication networks. Expanding the scope to critical infrastructures like transport and renewable energy further increases the number of required digital devices, all necessitating robust security measures.
Implementing DSbD for Enhanced Security
Implementing a DSbD approach in power grids and other critical infrastructures can help mitigate vulnerabilities and ensure secure operation. DSbD offers hardware-based security and efficient processing capabilities, potentially enhancing grid reliability, security, and efficiency.
Key Project Achievements
Successful Integration:
PNDC/University of Strathclyde integrated the Morello Board into a representative power network use case, focusing on Modbus TCP communication. A test setup was successfully built at PNDC to reflect a real-world scenario, demonstrating the Morello Board’s potential to enhance security in power networks.
Strategic Protocol Choice:
Modbus TCP was selected due to its widespread adoption and well-known security vulnerabilities, making it an ideal candidate for a compelling case study.
Security Analysis:
A comprehensive security assessment was carried out, identifying and addressing critical vulnerabilities such as buffer overflows and memory leaks. The project also employed white-box verification techniques and integrated static analysis tools to further strengthen the security posture.
Secure Communication Demonstrated:
Secure communication using Modbus TCP/IP protocols was successfully implemented, validating the feasibility of secure integration in power network environments.
Real-World Applicability:
The project demonstrated the practical use of the Morello Board in a realistic power network setting, highlighting its potential for broader industry adoption.
Collaborative Engagement:
Strong collaboration with industry stakeholders enabled effective knowledge sharing and the exchange of best practices throughout the project lifecycle.
Evaluation and Recommendations
Building on the successful physical demonstration at PNDC, the University of Strathclyde team advanced testing in a simulated environment, increasing scenario complexity to uncover additional potential attack vectors. This broader evaluation enabled a more in-depth assessment of the Morello Board’s security performance.
To push the boundaries further, the project began exploring AI-based techniques for improved vulnerability detection and threat mitigation—an innovative, forward-looking approach aligned with DSbD principles to enhance the security posture of critical infrastructure.
While the potential of DSbD and Morello is clear, challenges around cost, compatibility, and adoption must be addressed before widescale implementation in power systems becomes feasible.
Key Learnings
- The project underscored the importance of DSbD principles in securing modern power grids.
- Successful integration of Morello into a real-world power network use case was achieved.
- A comprehensive security analysis identified vulnerabilities in both Morello and existing systems.
- Morello outperformed an industry-standard x86 system in detecting memory safety issues.
- Collaboration with industry partners enabled valuable knowledge exchange and best practices.
Challenges Encountered
- The need for critical libraries (e.g., IEC 61850 and IEC 60870-5-104) became evident for future demonstrations.
- Technical complexity in setting up and configuring the test environment posed initial hurdles.
- Ensuring continuous operational availability while integrating advanced security features with Morello presented challenges.
- Legacy system integration across diverse OT/IT protocols introduced interoperability issues.
- Time constraints limited the breadth and depth of testing during the project.
Recommendations
- Strengthen Industry Collaboration:
Maintain active engagement with grid operators and industry stakeholders to explore integration opportunities, including continued collaboration to acquire essential libraries (e.g., IEC 61850) for future demonstrations. - Evaluate Enterprise-Scale Applications:
Investigate complex, enterprise-level use cases to demonstrate Morello’s capability in securing large-scale software systems. - Plan and Resource Future Trials:
Ensure appropriate allocation of technical and human resources to support future trials and evaluations. - Streamline System Integration:
Conduct in-depth assessments and develop comprehensive integration plans to simplify and accelerate adoption. - Expand Protocol Coverage:
Explore additional communication protocols beyond Modbus TCP, such as IEC 61850 and IEC 60870-5-104, to broaden applicability across power systems.
Future Focus Areas
As critical infrastructure, power networks demand the highest levels of security and resilience. However, the increasing digitalisation of these systems introduces new and evolving cyber threats. Robust, future-proof security measures are essential to ensure the continued safe and reliable operation of the grid.
The Morello Board, with its advanced memory safety features, offers a compelling solution for securing power network devices. By mitigating memory-related vulnerabilities—a common entry point for cyberattacks—Morello has the potential to significantly enhance the cyber resilience of power systems. This technology could play a transformative role in the future of power system security, aligning with the broader goals of the Digital Security by Design (DSbD) programme.
Looking ahead, the project will continue to build on current progress by expanding use cases, addressing technical barriers, and deepening the integration of DSbD principles into real-world systems.
Key future activities include:
Expanding use cases:
Apply Morello to a wider range of power grid protocols and scenarios to demonstrate its adaptability and relevance across diverse operational contexts.
Overcoming technical challenges:
Resolve outstanding issues related to system integration, library availability (e.g., IEC 61850), and time/resource constraints to enable smoother adoption.
Enhancing security posture:
Continue developing and refining methods—potentially including AI-based approaches—to strengthen the protection of power systems against emerging threats.
At PNDC, we recognise that securing the digital future of critical infrastructure is essential to achieving the UK’s net-zero ambitions. The DEFGRID project has demonstrated the value of DSbD technologies—particularly the Morello Board—in enhancing the cyber resilience of power networks. By combining expertise from industry and academia, we’ve taken meaningful steps toward reducing cyber risk across the utility sector. This work strengthens trust in next-generation infrastructure and paves the way for safer, smarter energy systems.
Acknowledgements
This project was delivered in collaboration with SGN, deltaflare, the University of Strathclyde Cyber Security Group (StrathCyber), ND Consult Technology Innovation Ltd, and was funded by Innovate UK (UKRI).
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