Attachment_1_-_DDSP_PLC_and_Controls_Upgrade_SOW_7.22.19.docx

Statement of Work for Programmable Logic Controllers (PLCs) and Controls Upgrade at DLA Distribution Susquehanna, Pennsylvania (DDSP)

July 2019

TABLE OF CONTENTS

introduction This document will describe the upgrade of the existing PLC’s in building 2001 and the introduction of an OT network. The PLC upgrade in conjunction with a new OT network will also change the existing network architecture, consolidating twenty-six (26) Allen-Bradly PLC’s to four (4) redundant PLC’s (two pairs). This will simplify and streamline the existing process and make any future upgrades or changes easier.

Purpose The purpose of this document is to outline specific deliverables required by the Contractor for the PLC upgrade on DLA’s OT network.

Scope The scope of this project is to design and document:

Replacement of approximately twenty-six (26) Allen-Bradley PLC-5/40’s and SoftLogix PLC’s with 2 redundant pairs (4 total) L85 processors Replacement of approximately one hundred and five (105) racks of Allen-Bradley 1771 I/O with Allen-Bradley 1756 I/O Installation of a new Fiber based OT network to 20 plant areas (pole mounted) and the MDF and Demarc rooms Installation of twenty (20) 2” conduit runs from the fiber optic panels to control cabinets Installation of approximately twenty (20) Layer2 panel switches to existing control panels with surface mounted fiber patch panels Installation of two (2) 240 strand fiber optic patch panels, one (1) in the ECS/MDF room and one (1) in the Demarc room Installation and programming of eighteen (18) Imaging scanners Installation and programming of twenty-six (26) Layer 2 POE Switches Installation of four (4) CAT6 cables within the existing 26 IDF cabinets for WLAN Access Points Installation of a 24 Port CAT6 patch panel in the existing 26 IDF cabinets Installation of Wireless Access Points to be extended 20’ below the bar joists Preform a wireless network review Installation of twenty-nine (29) L2 panel switches to tow-line control panels with surface mounted fiber patch panels The development of approximately 30 FactoryTalk View SE screens for controlling area processes Specification of Rockwell Software FactoryTalk SE Server Distributive Specification of Rockwell Software FactoryTalk AssetCentre Specification of Rockwell Software FactoryTalk Licensing Manager Specification of Rockwell Software FactoryTalk Directory Services Specification of Rockwell Software FactoryTalk Transaction Manager Development of an application framework to replace the existing tow-line keypads with a wireless solution Programing Allen-Bradley L85 processors

· Consolidation of 7 Pallet programs

· Consolidation of 10 Tote programs

· Consolidation of 6 Tow-line programs into the pallet PLC

· Coordinate the redesigned ECS application programming with the new architecture NIST/STIG Validation of all networking devices, forty-nine (49) L2 switches and Rockwell Software FactoryTalk application software Replacing eight (8) existing local HMI’s with twenty (20) new client/server-based HMI’s (Rockwell Software FactoryTalk RSView SE Distributive)

· Installation of NEMA 12 pedestal with 19” touchscreen

· Installation of industrial PC’s Furnish and install a GracePort on twenty (20) panels Provide a detailed installation and implementation schedule guide Program a new tow-line interface to replace the existing keypads (100) Furnish, configure and install twenty-five (25) handheld computers to replace the existing keypad functionality Configure five (5) laptops provided by DLA for Contractor AutoCAD drawings Submit a detailed training schedule, materials, and conduct Government personnel training Perform acceptance testing of the system

Unless explicitly stated within this SOW as a Government responsibility, activity, or function, all of the activities, services, labor, designs, supplies, material, equipment, components, and work products must be performed by and/or provided by the Contractor.

Glossary of Terms DLA: Defense Logistics Agency OT: Operational Technology (OT) – the hardware and software dedicated to detecting or causing changes in physical processes through direct monitoring and/or control of physical devices such as valves, pumps, etc.

OT is the use of computers/devices to monitor or alter the physical state of a system, such as the control system for a power station or the control network for a rail system. The term has become established to demonstrate the technological and functional differences between traditional IT systems and Industrial Control Systems environment, the so-called "IT in the non-carpeted areas". Examples of operational technology include:

· PLC's

· SCADA

· DCS

PLC/PAC: Programmable Logic Controller/Programmable Automation Controller is an industrial digital computer which has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, or robotic devices, or any activity that requires high reliability control and ease of programming and process fault diagnosis.

SCADA: Supervisory control and data acquisition (SCADA) is a control system architecture that uses computers, networked data communications and graphical user interfaces for high-level process supervisory management but uses other peripheral devices such as programmable logic controllers and discrete PID controllers to interface with the process plant or machinery.

DCS: Distributive Control System is a computerized control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is central operator supervisory control.

MDF: In telephony and networking, a main distribution frame (MDF or main frame) is a signal distribution frame for connecting equipment (inside plant) to cables and subscriber equipment (outside plant).

IDF: An intermediate distribution frame (IDF) is a free-standing or wall-mounted rack for managing and interconnecting the telecommunications cable between end user devices and a main distribution frame (MDF).

DSS: Distribution Standard System (Main Government computer system for business processes and acting as DLA’s Warehouse Management System (WMS) for both inventory movements and control) located off-site ECS: Equipment Control System (local interface to the PLCs from DSS and acting as DLA’s Warehouse Control System (WCS)) DH/DH+: The Allen-Bradley DH and DH+ systems are Local Area Networks (LANs). They connect programmable controllers, computers, and other devices so they can communicate and exchange data with one another.

SoftLogix: Control Systems are based on the Allen-Bradley Logix platform and seamlessly integrate machine control, motion control, and information processing. They take the control functions normally found in dedicated programmable controllers, encapsulate those functions in software and run them on a commercial operating system.

AWOS: Automatic Weigh and Offer System STIG: Security Technical Implementation Guide. A STIG is a specific set of configurations that make commonly used applications more secure against known vulnerabilities. STIGs create minimum security standards that apply to any application or system in use by the Department of Defense (DOD).

NIST: National Institute of Standards and Technology

Governing Codes, Regulations, Permits & Approvals The following list of specifications, standards and codes applies to the work covered within this SOW but may not be all-inclusive. The Contractor will be responsible to ensure that all such applicable regulations are satisfied, to include federal, state, and local requirements.

The latest edition of the following documents creates a part of this specification. The Contractor is responsible for determining all applicable codes and standards.

NIST Special Publication 800-37 https://csrc.nist.gov/publications/detail/sp/800-37/rev-1/final NIST Special Publication 800-53 https://nvd.nist.gov/800-53/Rev4/control/CA-2 Risk Management Framework https://nvlpubs.nist.gov/nistpubs/SpecialPublications/NIST.SP.800-37r1.pdf NIST Advanced Manufacturing Series 300-4, Guide to Industrial Wireless Systems Deployments https://www.nist.gov/publications/guide-industrial-wireless-systems-deployments DISA STIG https://iase.disa.mil/stigs/Pages/index.aspx Presidential Policy Directive – Critical Infrastructure Security and Resilience:

https://obamawhitehouse.archives.gov/the-press-office/2013/02/12/presidential-policy-directive-critical-infrastructure-security-and-resil Presidential Executive Order on Strengthening the Cybersecurity of Federal Networks and Critical Infrastructure:

https://www.whitehouse.gov/presidential-actions/presidential-executive-order-strengthening-cybersecurity-federal-networks-critical-infrastructure/8.

Occupational Safety and Health Administration (OSHA)29 CFR 1910 - Copies may be obtained at http://www.osha.gov National Electrical Manufacturers Association (NEMA) NEMA ICS 6 - Enclosures for Industrial Controls and Systems NEMA 12.1 - American National Standard for Electric Meters Code for Electricity Metering - Copies may be obtained at http://www.nema.org American Conference of Governmental Industrial Hygienists (ACGIH) - Industrial Ventilation Guide Copies may be obtained at http://www.acgih.org American National Standards Institute (ANSI) ANSI/ASME B20.1-1984- Safety standards for Conveyors and Related Equipment Copies may be obtained at http://www.ansi.org American National Standards Institute (ANSI) ANSI Z9.4 - Ventilation and Safe Practices of Abrasive Blasting Operations Copies may be obtained at http://www.ansi.org American Welding Society (AWS) - AWS D1.1/D1.1M Structural Welding Code - Copies may be obtained at http://www.aws.org National Fire Protection Association (NFPA) NFPA 70 - National Electrical Code NFPA 79 = National Electrical Code NFPA 91A - Exhaust Systems for Air Conveying of Vapors, Gas, Mists, and Particulate Solids - Copies may be obtained at http://www.nfpa.org DoDI 8500.01 “Cybersecurity”, March 14, 2014 DoD 8510.01 Risk Management Framework (RMF) for DoD Information Technology (IT) March 12, 2014.

American National Standards Institute (ANSI)/TIA-606-B Administrative Standard for the Telecommunications Infrastructure of Commercial Buildings ANSI/TIA-607-B Commercial Building Grounding and Bonding Requirements for Telecommunications ANSI/TIA-758-B Customer-Owned Outside Plant Telecommunications Cabling Standard ANSI/TIA/EIA-942 Data Centers ANSI/TIA/EIA-526-7 SM Fiber Testing ANSI/TIA/EIA-526-14-A MM Fiber Testing /A Upgrade Information Infrastructure Architecture (I3A) Guide UFC-3-580-01 Telecommunications Building Cabling Systems Planning And Design UFC-3-580-10N Design: Navy and Marine Corp Intranet (NMCI) Standard Construction Practices UFGS 16710 Building Telecommunications Cabling System UFGS 16402 Interior Distribution System - Electrical Systems Supporting Structure UFGS 16720N Administrative Telephone Equipment, Inside Plant DOD 5220.22M National Industrial Security Program Operating Manual (NISPOM) OPNAVINST 5100.23 Navy Occupational Safety and Health (NAVOSH) Program Manual Department of Defense Directive (DODD) 8100.2 Use of Commercial Wireless Devices, Services, and Technologies in the Department of Defense (DOD) Global Information Grid (GIG) UFGS 16711 Telecommunications Outside Plant (OSP) MIL-P-514 Plates, Identification, Instrumentation, and Marking MIL-PRF-61002 Identification Marking of U.S. Military Property MILSTD1472 Design Criteria Human Engineering MILSTD130 Identification Marking of U.S. Military Property 29 CFR 1910 Occupational Safety and Health Standards EM-385-1-1 General Safety Requirements MIL-STD-248 Welding and Brazing Procedures and Performance

The Contractor will notify the Government if an applicable code or regulation governing the work changes or is updated (or a change or update is anticipated) between the Task Order award date and installation of the work in sufficient time for the Government to evaluate (a) whether the work must conform to the changed or updated code or regulation and (b) whether the Contractor is entitled to additional compensation due to the changed code or regulation.

If the Contractor believes a code requirement is either unattainable or not cost effective, the Contractor must provide sufficient cost information and supporting documentation to the Government to support an analysis on whether a waiver request to the code requirement is reasonable and necessary.

The Government will have the final say in any concern regarding the satisfaction of applicable regulations and federal, state, and local requirements

The provided capability must be capable of obtaining and maintaining Agency authorization in accordance with the DoDI 8510.01 Risk Management Framework.

Overview The Defense Logistics Agency (DLA) is a combat support agency in the United States Department of Defense (DoD), with more than 26,000 civilian and military personnel throughout the world. Located in 48 states and 28 countries, DLA provides supplies to the military services and supports their acquisition of weapons, fuel, repair parts, and other materials. The agency also disposes of excess or unusable equipment through various programs.

DLA Distribution Susquehanna, Pennsylvania (DDSP) is a dual-sited operation, headquartered in New Cumberland, Pa. with additional facilities at Mechanicsburg, Pa., that provides nine million square feet of covered storage space, and as of 2015, maintains nearly 770,000 different National Stock Numbers (NSNs) worth $13 billion. It coordinates material management and distribution of mission critical items including military and commercial repair parts, industrial, medical supplies, tires, and aerial delivery equipment, optimizing all resources with a focus on safety, quality, and continuous process improvement. It serves as the eastern strategic distribution platform for the Department of Defense and primary distribution point for all branches of the U.S. Armed Services, Foreign Military Services, and other Federal agencies in the eastern U.S., and serves as their Consolidation & Containerization Point for transiting supplies to Central & South America, Europe, North Africa, and Southwest Asia.

Home to the largest distribution processing facility in DoD – the 1.7 million square foot Eastern Distribution Center handles 25 percent of DLA Distribution’s total receipt, storage, and issue of materiel worldwide. Susquehanna is the only center that receives, inspects, stages, and consolidates material for U.S. Army Security Assistance Command projects and acts as freight forwarder for Greece, Iraq, and Romania. Susquehanna has been managing the storage and distribution function of DLA Disposition Services collocated at the Mechanicsburg Site since 2014. As the largest DLA Distribution operation supporting the DLA Disposition Services, this initiative yields improved service for DLA customers and lower disposal costs for the DoD.

DLA New Cumberland facility was built around 1988-1989 and that era technology is still being used. The purpose of this document is to outline the existing outdated systems and make recommendations on an upgrade path that will be:

Secure Maintainable Efficient Modern Scalable The focus of this document is in the development of a new Ethernet based OT network and the upgrade of the existing PLC and I/O infrastructure.

The current network consists of Allen-Bradley Data-Highway/Data-Highway-Plus networks with some newer Ethernet to serial converters. There are no Ethernet connected systems or devices within the facility. There are about 20+ PLC subsystems connected throughout the facility via an Allen-Bradley DH/DH+ network. Each PLC controls a system or area/zone of the process. Each PLC is housed in a control panel that has all the necessary hardware and software to control the process. The panels are designed in a consistent layout with each section containing their necessary hardware:

Power (480v) Relays/Contactors Controls (PLC w/ I/O cards) 120v Separated HMI cabinet The current Warehouse Management System (WMS) deployed by DLA is the Distribution Standard System (DSS) which is the system of record for all material handling business processes and operational activities. DSS utilizes the Standard Movement Message (SMM) to convey warehouse location and destination information to the DLA’s Warehouse Control System (WCS), known as the Equipment Control System (ECS). ECS is a Government developed software system that was designed to meet the unique capability needs of the agency when facilities such as DDSP were constructed. Throughout this document identification of the “WMS” will refer to the currently deployed DLA software solution “DSS”. Additionally, identification of the “WCS” will refer to the currently deployed DLA software solution “ECS” respectively.

PLC’s at DDSP communicate with ECS via the aforementioned custom messaging and ECS acts in similar fashion as a WCS or middleware software application that receives commands from the WMS (DSS).

The general hierarchical architecture at DLA is shown in the following diagram:

Material movement commands are sent down from DSS via IBM WebSphere MQ (messaging queues) to ECS. ECS processes the commands and sends out messages to the appropriate warehouse subsystems. The subsystems can be either PLC’s, keypads, serial attached devices or interface computers. The subsystems communicating with ECS send back messages as appropriate. Those messages will be processed locally or returned to DSS via the MQ.

Messages destined to PLC’s can be processed locally and then be forwarded to other PLC’s depending on the type of transaction.

Background Existing System The Existing material handling system is based on an Allen-Bradley DataHighway/DataHighway+ network connecting 20+ Allen-Bradley PLC-5/40’s or SoftLogix processors. The following table lists the current PLC’s:

G29

D20

E28

*Beam ID is a designation to where a PLC is located relative to a structural beam, see CAD drawing.

The existing system is separated into two areas/zones, totes and pallets. These areas/zone PLC’s communicate both with their respective zone PLC’s as well as ECS. Messages are sent out to PLC’s using a message instruction.

List of current ECS subsystems running at DDSP:

ACT01 – Active Item and 3-to-1 Switch AWS02 – “Little” AWOS (backup AWOS system) AWS05 – “Big” AWOS (primary production AWOS system) KEY01-02 – Keypads (used to manually direct material flow in the distribution center) PAL01 – Pallet Conveyor in the Rack/Bin area RCK01 – Rack/DB40 storage area SRT01 – Sorter TIM01-22 – TIMs (TIMs are consolidation points for multiple keypads) TOT01 – Tote TOW01 – Towline

Message formats for the ECS subsystems running at DLA/DDSP:

The following section lists the exiting systems messaging formats to each sub-system along with the direction and message specifics.

ACT01 – Active Item and 3-to-1 Switch New Cumberland Active Item Package Interface establishes communications between the ECS and the New Cumberland Active Item Package System.

Communications protocol - RS-232 Serial ASCII-7 bit 9600-Baud Asynchronous Rules of Communication: When a message is received, and the checksums equate an ACK will be transmitted. When a message is received, and the checksums do not equate the NAK will be transmitted. Upon receiving a NAK the previous message will be retransmitted up to 3 times, then discarded. If no acknowledgement is received within ½ second the previous message will be retransmitted up to 3 times, then discarded. Message discards will be interpreted as jackpot (reject) moves.

Checksum: This character is the sum of all characters in the messages including STX and ETX. The checksum is and’ed with a 7F hex and then or’ed with a 40 hex to avoid conflicts with STX and ETX.

Startup messages must cause the PLC to trigger an alarm prior to equipment activation. After the alarm is triggered and the equipment is activated then send a startup complete message 07. Once all equipment stops send a shutdown complete message 07.

ECS (ACT01) PLC

Message Type - Char 2 - '08' PLC Number - Char 2 - '20' Status - Char 1 - '1' Startup ‘2’ Shutdown ETX - Char 1 - Hex '03' Checksum - Char 1

Message Type - Char 2 - '01' Scanner Number - Char 2 - '01' Destination - Char 3 - '001' ,'002', '003' Control Number - Char 7 ETX - Char 1 - Hex '03' Checksum - Char 1

(Valid)

ACK - Char 1 - Hex '06'

(Invalid)

NAK - Char 1 - Hex '15'

PLC ECS (ACT01)

DESCRIPTION

MESSAGE FORMAT

09 - AI Scanner Reply

Shows message received by scanner.

No reads will fill control number field with seven '?'s.

0 STX - Char 1 - Hex '02' 2-3 Message Type - Char 2 - '09' 3-4 PLC Number - Char 2 - '20' 5-12 Control Number - Char 7

1. ETX - Char 1 - Hex '03'

1. Checksum - Char 1

07 - AI Startup/ Shutdown Complete Msg

2-3 Message Type - Char 2 - '07' 3-4 PLC Number - Char 2 - '20'

1. Status - Char 1 - '4' or '5'

1. ETX - Char 1 - Hex '03'

AWS02 – “Little” AWOS (backup AWOS system) and AWS05 – “Big” AWOS (primary production AWOS system) The Interface allows for communications between ECS and PLC's, control number scanners and scales.

New Cumberland Message Formats from ECS/AWOS to PLC: Communications protocol - RS- 232 Serial ASCII-7 bit 9600-Baud Asynchronous with no parity and 2 stop bits.

ECS (AWS02/05) PLC

New Cumberland Message Formats from PLC to ECS/AWOS: Communications protocol - RS- 232 Serial ASCII-7 bit 9600-Baud Asynchronous even parity and 1 stop bits.

PLC ECS (AWS02/05)

Control Number Scanner

Read Status: #

Length: 8 Decimal Point: .

Fractional Weight: ## Unit Indicator: LB

PAL01 – Pallet Conveyor in the Rack/Bin area The New Cumberland Conveyor Interface allows for communications between the ECS and the New Cumberland Pallet Conveyor Controller.

Communications protocol - RS-232 Serial ASCII-8-bit data, 1 stop bit, no parity, 9600-Baud Asynchronous.

ECS (PAL01) PLC

(Startup/Shutdown) Purpose: This message is sent whenever the ECS starts up or shuts down. It is also sent when a zone that has been operating in semi-automatic mode is returned to automatic mode.

Message Type: 08 Length: 5

PLC Zone Number: ## Status Command (Start/Stop): #

Valid status commands:

1-Startup 2-Stop

Purpose: This message is sent when a pallet load is placed on the conveyor and needs to be moved to a destination. It identifies the load and destination to the PLC.

Message Type: 12 Length: 13

Destination: ### Load ID (Control Number): ##### Source: ###

PLC ECS (PAL01)

Purpose: This message is sent when a conveyor PLC zone status changes.

Message Type: 09 Length: 5

PLC Zone Number: ## Status: #

Valid modes include:

1-Automatic 2-Semi-Automatic 3-Manual 4-Start-Up Acknowledge 5-Shut-Down Acknowledge

Purpose: This message informs the ECS that a pallet load is present at induction or exit positions on the pallet conveyor.

Message Type: 11 Length: 5

Location (Station ID): ###

Purpose: This message informs the ECS that a pallet load has arrived at the designated conveyor or lane.

Message Type: 13 Length: 10

Location (Destination): ### Load ID (Control Number): #####

Purpose: This message is sent when the status changes for spurs V092-V095.

Message Type: 14 Length: 3

Conveyor Map (Bit Map): #

RCK01 – Rack/DB40 storage area The New Cumberland Rack Conveyor Interface allows for communications between the ECS and the New Cumberland Rack/DB40 Conveyor Controller.

Communications protocol - RS-232 Serial ASCII-8 bit data, 0 stop bit, no parity, 9600-Baud Asynchronous.

ECS (RCK01) PLC

Actual ECS message: $020102239ACCC74H$r$l (STX = $02, Message type = 01, scanner = 02, destination = 239, control number = ACCC74H, CR = $r, LF = $l)

PLC ECS (RCK01)

Scanner

Reply

SRT01 - Sorter The New Cumberland Sorter Interface provides a communications link between ECS and New Cumberland Sorters.

Communications protocol - RS- 232 Serial ASCII-8 bit 9600-Baud Asynchronous with 2-byte checksum and one stop bit.

ECS (SRT01) PLC

Purpose: This message sends the barcode ID and chute destination.

Message Type : 01 Length: 13

EDCCN : #######

Chute ID : ####

Sorter Status : #

Valid values for sorter status include:

1. - Startup Enable

1. - Shutdown Request

Complete Purpose: This message indicates that there are no more data records to be downloaded from the product file table.

Message Type : 06 Length: 2

Purpose: This message requests the current mode of sorter operation.

Message Type : 07 Length: 2

PLC ECS (SRT01)

Purpose: This message informs ECS that the destination database is full.

Message Type: 02 Length:2

Purpose: This message tells ECS which chute a particular item has been sent down.

Message Type: 03 Length: 18

EDCCN:#######

Chute ID: #### Status (Final Destination) : # Time : ####

Purpose: This message tells ECS that the purge product file table option has been selected.

Message Type: 05 Length: 2

Purpose: This message responds to a status inquiry by ECS.

Message Type: 08 Length: 3

Sorter mode: #

Valid Sorter modes include:

1. - Automatic

1. - Semi Automatic

1. - Manual

1. - Maintenance

1. - Startup completed

1. - Shutdown complete

TOT01 – Tote The New Cumberland Conveyor Interface allows for communications between the ECS and the New Cumberland Tote Conveyor Controller.

Communications protocol - RS-232 Serial ASCII-8-bit data, 1 stop bit, no parity, 9600-Baud Asynchronous

ECS (TOT01) PLC

Purpose: This message informs the PLC that a tote is to be moved to a new destination.

Message Type: 01 Length: 14

Chain ID: ### Chain Length: # Destination: ### Tote ID: #####

Purpose: This message informs the PLC that a workstation is disabled and that no loads are to be sent to that conveyor lane.

Message Type: 04 Length: 5 PLC Zone Number: ## Station ID: # (Bit map to identify conveyor lane)

Purpose: This message sets the inspection workstations for a certain type of inspection. This allows the workstation function to be changed based on workload requirements.

Message Type: 07 Length: 6

Random Stations (Bit Map): # Retrograde Stations (Bit Map): # New Procurement Stations (Bit Map):# Depot Property Stations (Bit Map): #

Purpose: This message is sent whenever the ECS starts up or shuts down. It is also sent when a zone that has been operating in semiautomatic mode is returned to automatic mode.

Message Type: 08 Length: 5

PLC Zone Number: ## Status Command (Start/Stop): #

Valid status commands:

1-Startup 2-Shutdown

PLC ECS (TOT01)

Purpose: This message is sent when a conveyor PLC zone status changes.

Message Type: 09 Length: 5

PLC Zone Number: ## Status: #

Valid modes include:

1-Automatic 2-Semi-Automatic 3-Manual 4-Start-Up Acknowledge 5-Shut-Down Acknowledge

TOW01 – Towline The New Cumberland Towline Interface provides a communications link between ECS and the New Cumberland Towline Controller.

Communications protocol - RS - 232 Serial ASCII-8 bit 9600-Baud Asynchronous with one stop bit.

ECS (TOW01) PLC

DESCRIPTION

MESSAGE FORMAT

Purpose: This message is sent to indicate to the PLC that a cart is to be moved from one location to another.

Message Type : 03 Length: 18

Cart ID : #### Destination : #### Release Location (source) : #### Chain ID : ### Chain Length : #

Upload Command Purpose: This message is sent whenever ECS starts up or shuts down or when an upload is requested.

Message Type : 06 Length: 6

Status Command (Start/Stop) : ## Upload Request : ##

Valid Contents of the Status Field:

0 - status update 1 - shutdown 2 - startup

Valid Contents of the Upload Request:

07 - upload destination file 10 - upload first loop tracking file 11 - upload second loop tracking file 0 - no upload

Purpose: This message is sent when, under certain conditions, a chain of carts must be dissolved. This message uses the chain ID to abort this chain.

Message Type: 09 Length: 7

Chain ID : #### Chain Length: #

Purpose: This message requests the destination, recirculation count, chain ID, and chain length of a particular cart.

Message Type : 12 Length: 6

Cart ID : ####

Purpose: This message is sent when a workstation has been reserved for a chain of carts, but not all carts have arrived. This message uses the workstation ID to dissolve the chain and release the reserved workstation.

Message Type : 14 Length:6

Spur Number : ####

Purpose: This message is sent to notify the PLC that a spur is being added to a given inspection work area.

Message Type : 15 Length:10

Spur ID : #### Spur Type : ####

PLC ECS (TOW01)

Purpose: This message tells ECS that a cart has arrived at a towline spur or transfer.

Message Type : 01 Length: 10

Cart ID : #### Location : ####

Purpose: This error message indicates that a cart has not arrived at its destination correctly. The cart has passed its destination spur or transfer, a cart doesn’t unload at an automatic unloader, or a loaded cart has arrived at a loading station.

Message Type : 02 Length: 10

Cart ID : #### Location : #### Valid Location Fields include either a spur number, loader ID, or unloader ID.

Purpose This message identifies the location of a cart. It has either been successfully unloaded by an automatic unloader, it has arrived at a loading station, or it has arrived at a station with a scale or sizing equipment.

Message Type : 04 Length: 10

Cart ID : #### Location : #### Valid Location Fields include either a spur number, loader ID, or unloader ID.

Purpose This message is sent when a loop status, spur status, or transfer status changes (up or down).

Message Type : 05 Length: 32

Status bit map : 15 16 bit words in length This status may pertain to a loop, spur, or transfer.

Purpose This message contains the contents of the cart destination file.

Message Type : 07 Length: 2402

Cart Destinations : (2400 bytes for character destinations)

Purpose: This message is sent when a towline PLC zone status changes.

Message Type : 08 Length: 4

PLC Zone Number : # Status : #

Valid status modes for a zone include:

1 - automatic 2 - semi-automatic 3 - manual 4 - start-up acknowledge 5 - shut-down acknowledge

Purpose: This message contains the contents of a loop-tracking file.

Message Type : 10 Length: Variable

Tracking File Contents: Length of contents varies depending on the loop.

Purpose: This message contains the contents of a loop-tracking file.

Message Type : 11 Length: Variable

Tracking File Contents: Length of contents varies depending on the loop.

Cart ID : #### Destination : #### Chain ID : ### Chain Length :# Recirculation Count : #

Proposed New System The new system model will include both a new logical and physical architecture that incorporates the latest in networking, security hardware, software and methods. The OT network uses the Purdue Model for Control Hierarchy (reference ISBN 1-55617-265-6). The Purdue Model is a common and well-understood model in the manufacturing industry that segments devices and equipment into hierarchical functions. It has been incorporated into many other models and standards in the industry. Based on this segmentation of the plant technology, the International Society of Automation ISA-99 Committee for Manufacturing and Control Systems Security has identified the levels and logical framework. Also reference DISA STIG, NIST Special Publication 800-37 and NIST Special Publication 800-53.

In its simplest form, the Purdue Model separates the systems into a logical framework divided into five zones and six levels of operations. The Purdue model uses the concept of zones to subdivide an Enterprise and ICS (Industrial Control Systems) network into logical segments comprised of systems that perform similar functions or have similar requirements.

Enterprise Zone - Level 5: Enterprise Level 5 is where corporate IT infrastructure systems and applications exist. Typically, VPN remote access and corporate Internet access services live in this level, to name a few. Direct communication between systems in the enterprise zones and the ICS environment is usually discouraged based on the level of risk that this would expose the organization to. A better approach is to manage access into the ICS environment through a Demilitarized Zone (DMZ) (Cisco and Rockwell Automation, 2011).

Enterprise Zone - Level 4: Site Business Planning and Logistics Level 4, often seen as an extension of Level 5, houses IT systems that deal with reporting, scheduling, inventory management, capacity planning, operational and maintenance management, e-mail, phone and printing services. The services, systems and applications in Levels 4 and 5 are normally managed and operated by the IT organization (Cisco and Rockwell Automation, 2011).

Manufacturing Zone - Level 3: Site Manufacturing Operations and Control The systems in Level 3 are often responsible for managing control plant operations to produce the desired product. Applications, services, and systems that are found at this level include:

· Plant historian

· Production reporting system

· Production scheduling systems

· Reliability assurance

· Engineering workstations

· Network File servers

· IT services such as DNS, DHCP, Active Directory, and NTP

· Remote access services

· Staging area

· FactoryTalk Applications The systems and applications in Level 3 communicate with the systems in Enterprise Zone through a DMZ. Direct communication between systems in Manufacturing and Enterprise zones is discouraged. Additionally, systems in Level 3 may communicate with systems in Levels 1 and 0 (Cisco and Rockwell Automation, 2011).

Cell/Area Zone - Level 2: Area Supervisory Control Level 2 systems include the manufacturing operations equipment for an individual production area. Level 2 typically includes:

· Human Machine Interfaces (HMI)

· Alarms/Alert systems

· Control room workstations These systems may communicate with systems in Level 1. Additionally, they may also interface with systems in the Manufacturing and Enterprise zones through the DMZ (Cisco and Rockwell Automation, 2011).

Cell/Area Zone - Level 1: Basic Control Level 1 includes process control equipment that receives input from sensors, processes the inputted data by using control algorithms, and sends the outputted data to a final element. Devices in this level are responsible for continuous, sequence, batch and discrete control. Some devices that exist in the level are Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), and Remote Terminal Units (RTU). These devices run Contractor-specific operating systems and are programmed and configured from engineering workstations (Cisco and Rockwell Automation, 2011).

Cell/Area Zone - Level 0: Process Level 0 includes the sensors and instrumentation elements that directly connect to and control the manufacturing process. These devices are controlled by devices found in Level 1 (Cisco and Rockwell Automation, 2011).

The sustainment of Levels 0-2 will be managed by maintenance contracts held by DLA Distribution. The sustainment of Levels 3-5 will be handled by DLA/J6, including the core switches and VMware virtual servers that will be supporting Factory Talk Applications. Section 5 of this PWS clearly defines the detailed scope of work for the initial standup for the PLC and their supporting equipment/applications.

The following diagram represents the overview design of the OT core network from building 2001 to the local vSphere in building 430. The requirements for all network connected switches are to have no single point of failure. To accomplish this, both DLA and the Contractor must use stacked switches at the core and EtherChannel from the core to the IDF and panel switches.

The design of this network is a fiber star topology from core switches to panel switches. All the connections between the MDFs and the IDFs will be completely fiber. This negates the need to run 120v power to the twenty (20) IDF cabinets.

Site Description The system modifications will be installed in throughout building 2001 – Eastern distribution Center (EDC) at DLA Distribution New Cumberland, PA (DDSP), 2001 Mission Drive, New Cumberland, PA 17070-5000. The EDC is an approximately 2.7million square foot logistics and distribution operations.

Normal working hours for the site are 06:00 hours to 22:30 hours Monday through Saturday Eastern Standard Time (EST).

Due to the mission of DLA to provide worldwide logistics support for the missions of the Military Departments and the Unified Combatant Commands under conditions of peace and war, there is a possibility of surge capability during contingency operations. This surge capability will flex to a 24x7 operation.

Work Area Description The control panels are located throughout Bldg. 2001 (the EDC).