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Explore our comprehensive Cyber Security Services, featuring Red Team Assessment, Penetration Testing, Digital Forensics, Web Application Testing, and Network Security Audit. Our expert solutions ensure robust protection for your digital assets and infrastructure.

OT · ICS · SCADA Security Audit · Safe Methodology

Secure the plant.
Keep production running.

A safe, non-disruptive audit of your operational-technology estate — SCADA, PLCs, HMIs, DCS, historians, and safety instrumented systems. Aligned with IEC 62443, NIST SP 800-82, NERC CIP, and MITRE ATT&CK for ICS. We assess the risks that attackers exploit and that auditors ask about — without ever touching a live process.

IEC 62443
Zones & Conduits
NIST 800-82
Rev. 3 Aligned
Production-Safe
Passive-First Method
insec@plant ~ purdue-model --scan=passive
◈ Purdue Model · Zone Segmentation Audit
L5

Enterprise Network

ERP · mail · internet

GOOD
L4

Business Planning

MES · logistics · scheduling

MED
— IDMZ · Broker & Jump-Host Zone —
L3

Operations Mgmt

Historian · engineering WS

MED
L2

Supervisory Control

SCADA · HMI · OPC servers

HIGH
L1

Basic Control

PLCs · RTUs · IEDs

CRIT
L0

Process / Field

Sensors · actuators · SIS

SAFETY
▸ 14 conduits · 3 unauthorized flows detected passive · v4
87%
of OT orgs hit by cyber incident last 12m
60%
had IT → OT lateral movement
$2M+
avg cost of 1 hour of production downtime
Level 0/1
where safety impact lives · our focus
// The 9-Step Framework

Passive-first. Safety-first. Always.

OT is not IT. We adapt every method to plant reality — walk-downs before scans, read-only before anything active, and engineering-led sign-off on each step.

01 · SCOPE

Scoping & Safety Contract

Plant walk-through, process criticality, MOC & PSSR integration, abort criteria, engineering sponsor.

02 · INVENTORY

Asset & Data-Flow Inventory

Passive capture, historian exports, config reviews, asset tags, cable-tracing where practical.

03 · ZONES

Zone & Conduit Assessment

Purdue-model alignment, IEC 62443 zone & conduit design review, IDMZ validation.

04 · ACCESS

Remote & Vendor Access

Jump hosts, vendor VPN, remote-support tools (TeamViewer, AnyDesk), identity hygiene.

05 · DEVICES

PLC / HMI / SCADA Review

Firmware & patch posture, auth, debug interfaces, project-file integrity, hardcoded creds.

06 · PROTO

Protocol Analysis

Modbus, DNP3, EtherNet/IP, Profinet, IEC 61850, OPC UA traffic review · passive only.

07 · SAFETY

SIS / Safety System Review

TRICONEX, SIMATIC Safety, HIMA & similar — isolation, lifecycle, bypass controls.

08 · DETECT

Monitoring & IR

OT NDR coverage (Dragos, Claroty, Nozomi), SIEM integration, OT-specific playbooks.

09 · REPORT

Report & SL-T Mapping

IEC 62443 SL-T vs SL-A gap analysis, engineer-grade fixes, regulator-ready evidence pack.

// Plant-Safe Protocol

No active scans. No surprise traffic. No downtime.

Every action is cleared by your engineering lead. We treat the plant like a cardiac ward — measure without disturbing.

Passive-First

Port mirrors, historian exports, documented configs. Active scans only in isolated test banks.

Engineering Sign-Off

Every in-scope action is logged & signed by the plant engineering sponsor before execution.

MOC Compliant

Integrated with your Management of Change and Pre-Startup Safety Review processes.

Vendor Warranties Preserved

No firmware modification, no parameter changes, no rehoming of configs · warranties intact.

Segregated Roles

OT-certified auditors (IEC 62443 practitioner) lead plant-floor work · not IT pentesters.

Safety-System Boundaries

SIS nodes are reviewed via docs & isolated test-benches only · never touched in-situ.

// Protocol Coverage

Every protocol your plant floor speaks.

Our analysts are fluent in the OT protocol stack — not just familiar with it. We can read packet captures the way your control engineers read ladder logic.

Modbus
TCP / RTU / ASCII

Function-code abuse, unit IDs, coil/register integrity.

DNP3
Serial / IP · Secure Auth

SAv2/5, unsolicited responses, master-outstation audit.

EtherNet/IP
CIP · Rockwell

CIP services, PCCC legacy, explicit/implicit messaging.

Profinet
RT/IRT · Siemens

GSDML review, DCP abuse, S7 communication auth.

S7 / S7+
Siemens PLC

Password bypass CVEs, TIA project integrity, anti-replay.

IEC 61850
MMS / GOOSE / SV

Substation automation, GOOSE spoofing, IED cert chain.

OPC UA / DA
Interop

Security modes, UA certificates, legacy DCOM exposure.

BACnet
Building Auto

BBMD, network numbers, device-ID collisions, writes.

IEC 60870-5
104 / 101

Telecontrol, ASDU abuse, link-layer integrity.

HART-IP
Field Device

Device-description abuse, gateway-level isolation.

MQTT / Sparkplug
IIoT broker

ACLs, TLS, topic hygiene, rogue publisher detection.

Proprietary
Vendor-specific

ABB, Honeywell, Emerson, Yokogawa, Schneider, GE.

// Assets We Audit

From sensor to supervisor.

PLCs & RTUs

Controllers at the heart of process control.

  • Siemens S7-1200/1500/300/400
  • Rockwell ControlLogix / CompactLogix
  • Schneider Modicon M580/340
  • ABB AC500 · GE RX3i · Mitsubishi
  • Firmware CVE · default creds
  • Program integrity & backup

HMI / Engineering WS

Operator consoles & programming workstations.

  • Siemens WinCC · TIA Portal
  • Rockwell FactoryTalk · Studio 5000
  • Wonderware / AVEVA InTouch
  • GE iFIX · Ignition SCADA
  • Patch posture · USB policy
  • Account hygiene · project storage

DCS & Historians

Supervisory and data-archiving backbones.

  • Honeywell Experion · Emerson DeltaV
  • Yokogawa CENTUM · ABB 800xA
  • AVEVA PI · Wonderware Historian
  • IDMZ broker & data replication
  • Role model & auth hygiene
  • Backup/restore lifecycle

SIS & Safety Systems

Systems that keep operators and plants alive.

  • Schneider TRICONEX Tricon/Trident
  • Siemens SIMATIC Safety
  • HIMA HIMax / HIMatrix
  • Rockwell GuardLogix
  • Lifecycle & bypass controls
  • Review by docs & test-bench only

Networks & Field Buses

The transport layer under all process traffic.

  • OT switches (Cisco IE · Hirschmann)
  • Industrial firewalls (Palo · Fortinet · Tofino)
  • VLAN / MAC hygiene
  • Wireless (ISA100 · WirelessHART)
  • Serial-to-IP gateways
  • Fieldbus exposure surfaces

Remote & Vendor Access

The most common attack path into OT.

  • Vendor VPN · jump-host inventory
  • TeamViewer / AnyDesk / RDP
  • Secure-remote-access gateways
  • MFA · session recording
  • Third-party access reviews
  • Break-glass procedures
// Industry Verticals

Domain-aware auditors — not IT folks playing plant.

// POWER

Electric Utilities

Transmission, distribution, substations. NERC CIP, IEC 61850, protection relays, RTUs, SCADA.

// OIL & GAS

Upstream · Mid · Down

Wellhead automation, pipeline SCADA, refinery DCS, terminal automation, custody transfer.

// WATER

Water & Wastewater

Pumping stations, treatment plants, distribution SCADA, chemical dosing, SIS alignment.

// PHARMA

Pharma & Biotech

GMP systems, batch control, 21 CFR Part 11, clean-room automation, cold-chain.

// MANUFACTURING

Discrete & Process

Automotive, FMCG, metals & mining. Robotics, line automation, MES integration.

// TRANSPORT

Rail & Ports

Signalling, rolling stock, port cranes, terminal operating systems, IEC 62443-3-3.

// BUILDING

Smart Buildings / Campuses

BMS, HVAC, access control, elevators. BACnet, KNX, LonWorks. Converging IT/OT/IoT.

// DATA CENTERS

DC Infrastructure

UPS, cooling plants, generators, BMS — the OT that keeps IT alive.

// DEFENCE

Defence & Aerospace

Protected-environment audits under DPSU / MIL norms & national-critical-infra rules.

// Standards & Regulation

Findings mapped to the frameworks regulators check.

IEC 62443

Zones & conduits · SL-T vs SL-A · Foundational Requirements.

NIST SP 800-82

Rev. 3 · OT guide & overlay to 800-53 controls.

MITRE ATT&CK ICS

Tactic-technique mapping for every finding.

NERC CIP v5/6

North-American bulk-electric compliance support.

API 1164

Pipeline SCADA security alignment (upstream/mid).

AWWA · J100

Water-sector risk & resilience methodology.

ISO/IEC 27019

Energy-industry security control set.

India NCIIPC

Critical-infrastructure framework alignment.

CEA · CERT-In

Power-sector Indian regulator directives.

21 CFR Part 11

Pharma electronic-records integrity.

TSA Pipeline SD

US TSA security directives support.

NIS2 (EU)

Essential & important entities OT obligations.

// Deliverables

A plant you can trust — and evidence an auditor accepts.

Zone & Conduit Map

Current-state Purdue diagram, zone classification, conduit inventory, and IDMZ validation.

SL-T Gap Analysis

Per-zone target vs achieved security level with specific remediation steps per foundational requirement.

Asset & Vuln Inventory

Complete OT asset list with firmware, CVE exposure, criticality tier, & patch recommendation.

Remediation Roadmap

Phased plan: quick-wins in days, segmentation in weeks, zone redesign in quarters.

Detection & IR Blueprint

OT-NDR vendor fit, SIEM use cases, OT-specific incident playbooks, tabletop-ready scenarios.

Regulator Evidence Pack

Control-by-control evidence for NERC CIP · NIS2 · NCIIPC · CEA · API 1164 · NIST 800-82.

// Engagement Timeline

Site visit to roadmap in 5-8 weeks.

WEEK 0

Scoping & Safety

Sites, criticality, MOC integration, engineering sponsor, abort criteria, vendor coordination.

WEEK 1

Desk Review

Docs: P&IDs, architecture, asset lists, procedures, prior audits. Interview plan.

WEEK 2-3

Site Visit & Capture

Walk-down, passive traffic capture, interviews, config reviews, evidence collection.

WEEK 4-5

Analysis & Gap Mapping

Zones/conduits, SL-T vs SL-A, CVE cross-reference, vendor-specific hardening gaps.

WEEK 6

Reporting & Debrief

Executive + engineering reports. Joint walkthrough with plant & corporate security.

WEEK 7+

Remediation Support

Architecture support, vendor coordination, detection engineering, re-audit on remediation.

// FAQ

What operations and security teams ask first.

Will your audit cause plant downtime?
No. Our methodology is passive-first: port mirrors, historian exports, walkdowns, and interviews. Any active scan — if allowed at all — happens in a disconnected test bench, not on live controllers. Every in-scope action is signed by the plant engineering lead before execution.
Will this void our vendor warranties?
No. We never modify firmware, change parameters, or re-home configurations. All evidence is collected in a read-only manner. Where documentation requires vendor authorization, we coordinate with the OEM directly.
Do you touch Safety Instrumented Systems?
Only via documentation review and, when available, isolated test benches. SIS nodes in production are reviewed by design documents, cause-&-effect matrices, and cybersecurity lifecycle records — never by live probing.
Are your auditors IT or OT trained?
OT-specialist. Our plant-floor auditors hold IEC 62443 certifications, have PLC/HMI hands-on experience (often from prior control-engineering careers), and are paired with IT security leads for the convergence areas.
Can you help us achieve IEC 62443 certification?
Yes. We deliver SL-T vs SL-A gap analysis, remediation roadmap, and evidence for IEC 62443-2-1 (asset owner) or 62443-4-1 / 4-2 (product supplier) certification journeys. We've supported clients through TÜV and UL audits.
Does this work for remote assets (wellheads, substations, pipelines)?
Yes. We combine remote evidence collection (historian pulls, config exports) with selective site visits to representative remote assets. Telematics-heavy architectures (SCADA to wellhead RTUs) get dedicated attention.
What about air-gapped facilities?
We perform the audit fully on-site with offline tooling. Evidence is transferred through your approved data-diode or sanitised media procedures. We carry our own write-blocked collection hardware where needed.
How much does it cost?
Single-site audits typically ₹8L–₹25L depending on scope and verticals. Multi-site enterprise programs are quoted per-site after scoping. Fixed quote inside 48 hours of the scoping call.
// Get Started

Know your plant's cyber posture — without shutting it down.

Book a 30-minute scoping call. Tell us about your process, sites, and regulator drivers — we'll send a fixed quote within 48 hours and propose the safest execution plan.