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Control for IT/OT convergence

Secure IT/OT convergence through physical boundary enforcement.

Convergence delivers operational efficiency but removes the air gap that protected industrial systems for decades. Control restores the physical boundary while preserving the data flows that convergence enables.

  • Eroded air gaps
  • Legacy system exposure
  • Shared management planes

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The challenge

Convergence creates pathways industrial systems were never designed to defend.

You cannot firewall your way to an air gap. If a packet can traverse from your IT network to your OT environment, the boundary exists only in your network diagram.

  1. The IT/OT boundary is enforced through physical disconnection, not firewall rules.

  2. Monitoring data flows from OT to IT through controlled transfer mechanisms.

  3. IT and OT management infrastructure sits on physically separate networks.

Challenge 1

Eroded air gaps.

The physical separation that protected OT systems has been replaced with firewalls and VLANs, bypassed through misconfigurations, credential theft and zero-day vulnerabilities.

Answered byPhysical boundary enforcement

Challenge 2

Legacy system exposure.

Industrial control systems running decades-old software are now reachable from IT networks, and many cannot be patched or run endpoint protection.

Answered byOne-way monitoring flows

Challenge 3

Shared management planes.

IT and OT often share authentication infrastructure, jump servers and management tools, so a compromise of the IT management plane reaches OT control systems.

Answered bySeparate management planes

The scenario

Scenario: an IT compromise reaching industrial control systems.

A firewall with 47 rules between IT and OT was traversed in three hours by penetration testers. Step through it, or play it through.

Step 1 of 2

The attack path

A water treatment facility connects its SCADA systems to the corporate IT network. An attacker compromises a corporate workstation through a phishing email and discovers the jump server used for SCADA access.

Using harvested credentials, they traverse from the IT network to the OT environment, gaining access to programmable logic controllers that manage chemical dosing.

The path
Always there
What the attacker needs
A foothold and time

An illustrative scenario.

Physical
Separation between IT and OT management planes
Scheduled
OT-to-IT monitoring flows
One command
To sever all IT/OT connections
Logged
Evidence for IEC 62443 zones and conduits

Where Control breaks the chain

How Control stops IT incidents bleeding into OT.

IT and OT convergence is efficient, but it gives an IT compromise a direct road into safety-critical control systems. Control keeps the convergence working without letting an IT incident become a process-safety incident.

  1. Physical severFirebreakPhysically opens or closes connection paths to prevent unauthorised access and stop attack progression.
  2. Zone boundaryIsolateSeparates systems and networks into controlled zones to reduce lateral movement and enforce trust boundaries.
  3. Time-bound pathRelayAllows connectivity only when needed, for a defined purpose, under controlled conditions and for a limited time.
  4. Named accessLockRestricts access through identity, authority, policy, permission and operational controls.
  5. Integrity checkValidateChecks whether a request, command or approval should proceed before access, action or transfer is allowed.
  6. Trigger, act, terminateExecuteInitiates control actions when a policy, approval, schedule, incident state or supervisory override requires it.

Explore the Control Blueprints

Capabilities

What you get with every deployment.

Six things Control gives the team, from the first boundary to the audit afterwards.

IT/OT

Physical boundary enforcement

The IT/OT boundary is enforced through physical disconnection, not firewall rules.

IT/OT

One-way monitoring flows

Monitoring data flows from OT to IT through controlled transfer mechanisms.

IT/OT

Separate management planes

IT and OT management infrastructure sits on physically separate networks.

IT/OT

Emergency OT isolation

A single authorised command physically severs all IT/OT connections.

IT/OT

Conduit activity logging

Every data transfer and maintenance session across the IT/OT boundary is logged.

IT/OT

IEC 62443 evidence

Physical zone and conduit architecture that can help support IEC 62443 requirements.

Adoption guide

From first boundary to routine operation.

Four steps, piloted on one site before it extends across the estate.

  1. 1

    Convergence point audit

    Map every connection between IT and OT environments, including shared management infrastructure.

  2. 2

    Zone and conduit design

    Design physically separated zones aligned to the Purdue model, with controlled conduits.

  3. 3

    Non-critical system pilot

    Deploy physical boundary enforcement on a non-critical OT segment, testing monitoring data flows.

  4. 4

    Full OT deployment

    Extend to all IT/OT boundaries, with automated compliance evidence and continuous conduit monitoring.

Questions

What teams ask first

Yes. Monitoring data flows from OT to IT through controlled transfer mechanisms, without a persistent path from IT into OT.

During authorised maintenance windows. The jump server connects to OT infrastructure only for the window, with named access and approval.

Yes. Control sits on the paths between zones, not inside the control systems, so existing SCADA and DCS keep running as they are.

Zones and conduits are designed around the Purdue levels, with a physical boundary at each step.

All questions

Speak to the team to organise a PoC.

Walk through your blueprint with the Firevault team and scope a proof of concept on your estate. 30 minutes, no sales pitch.