--- title: "Physical Control for OT Environments | Control" url: https://fire-vault.com/control-for-ot-environments description: "Protect your Operational Technology (OT) and industrial control systems with physically enforced network segmentation and access control. Explore." lang: en-GB --- Network Evolution & Rapid Protection (#NEARP) # Physical Network Governance for Operational Technology Industrial control systems, SCADA networks, and manufacturing processes were built for reliability, not cybersecurity. As IT/OT convergence accelerates, these systems face threats they were never designed to withstand. Back to Control: https://fire-vault.com/solutions/control Image: Industrial control environment with operational technology systems (https://fire-vault.com/assets/oss-industry-ot-CUdZsi1F.jpg) The exposure in numbers 01 IT-to-OT crossover pathways Zero IT-to-OT crossover pathways 02 Operational continuity maintained 24/7 Operational continuity maintained 03 Governance modules for OT isolation 9 Governance modules for OT isolation 04 IEC 62443 compliance evidence Full IEC 62443 compliance evidence The Challenge ## OT environments are increasingly exposed. 01 ### IT/OT Convergence Shared connectivity between IT and OT networks exposes industrial systems to IT-borne threats. 02 ### Legacy Systems Legacy OT systems lack authentication and encryption, and patching requires downtime. 03 ### Configuration Tampering Attackers alter PLC programs and SCADA configurations with changes that go undetected for weeks. > If your IT network can reach your OT network, so can an attacker. The only real air gap is a physical one, not a firewall rule, not a VLAN, not a DMZ. Control enforces physical IT/OT separation at the hardware level. The Scenario ### Scenario: Ransomware Crosses IT into OT A manufacturing plant's IT network is compromised through a phishing email targeting the finance team. The ransomware spreads laterally across the corporate network within 4 hours. Because the historian server bridges IT and OT, sharing a network path for reporting, the ransomware reaches the OT network by hour 6. PLC configurations are encrypted, SCADA displays go dark, and the plant loses supervisory control of three production lines. Recovery takes 18 days because backup PLC configurations were stored on a network-attached share, also encrypted. With Control, the Isolate module physically disconnects OT backup data from IT networks. The Transfer module governs any data movement between zones through policy-controlled windows. The ransomware reaches IT but cannot cross a connection that physically does not exist. "We had a firewall between IT and OT. We thought that was an air gap. When the ransomware jumped across, we realised a firewall rule is just software, and software can be bypassed. We needed physical disconnection." Module deployment · OT estate ## Where each Control module is deployed across the Purdue layers. Most OT estates still look like a stack: enterprise on top, an industrial DMZ in the middle, process control and supervisory layers below it, and safety at the bottom. Control puts a physical boundary at every step so a problem at one layer does not propagate to the next. Grounded in ISA-95 / Purdue, IEC 62443-3-3 and NIST SP 800-82 Rev. 3. L5 Internet / Cloud External Cloud services Image: FV-Firebreak module icon (https://fire-vault.com/assets/firebreak-icon-7zSCkB1t.png) Firebreak Image: FV-Validate module icon (https://fire-vault.com/assets/vault-icon-CD3Pv4ri.png) Validate External traffic terminates in the perimeter. L4 Enterprise IT ERP Email SOC / SIEM Business systems. Not part of the process. Image: FV-Isolate module icon (https://fire-vault.com/assets/isolate-icon-B9t8fl3o.png) Isolate Image: FV-Firebreak module icon (https://fire-vault.com/assets/firebreak-icon-7zSCkB1t.png) Firebreak Enterprise cannot reach the DMZ on its own terms. L3.5 Industrial DMZ DMZ · trust boundary Jump server Patch & AV Data broker All IT/OT traffic terminates here. All IT/OT traffic terminates here. Image: FV-Relay module icon (https://fire-vault.com/assets/relay-icon-CVhJDRO7.png) Relay Image: FV-Validate module icon (https://fire-vault.com/assets/vault-icon-CD3Pv4ri.png) Validate Image: FV-Transfer module icon (https://fire-vault.com/assets/transfer-icon-DqGa0PQI.png) Transfer Data moves through the DMZ on controlled routes only. L3 Operations OT Historian MES Engineering Image: FV-Isolate module icon (https://fire-vault.com/assets/isolate-icon-B9t8fl3o.png) Isolate Engineering and SCADA on separate fabrics. L2 Supervisory OT SCADA HMI Image: FV-Execute module icon (https://fire-vault.com/assets/execute-icon-kJl5Gtmk.png) Execute Control actions need approval. L1 Basic control Field PLCs DCS RTUs Image: FV-Isolate module icon (https://fire-vault.com/assets/isolate-icon-B9t8fl3o.png) Isolate Image: FV-Lock module icon (https://fire-vault.com/assets/lock-icon-UU3vOaKE.png) Lock Safety is reachable by named operators only. SIS Safety systems Field Safety PLC ESD Safety integrity. Last line. Safety integrity. Last line. Image: FV-Lock module icon (https://fire-vault.com/assets/lock-icon-UU3vOaKE.png) Lock Field assets named. L0 Physical Field Sensors Actuators OSS Crown jewels Off-network Detail callout · A Offline Secure Storage PLC programs, DCS baselines, SIS logic, recipes and the records to rebuild from after an incident. Offline by design · secure by default Modules & symbols Image: FV-Firebreak module icon (https://fire-vault.com/assets/firebreak-icon-7zSCkB1t.png) Firebreak Physical sever Image: FV-Validate module icon (https://fire-vault.com/assets/vault-icon-CD3Pv4ri.png) Validate Integrity check Image: FV-Isolate module icon (https://fire-vault.com/assets/isolate-icon-B9t8fl3o.png) Isolate Zone boundary Image: FV-Relay module icon (https://fire-vault.com/assets/relay-icon-CVhJDRO7.png) Relay Time-bound path Image: FV-Transfer module icon (https://fire-vault.com/assets/transfer-icon-DqGa0PQI.png) Transfer Controlled move Image: FV-Execute module icon (https://fire-vault.com/assets/execute-icon-kJl5Gtmk.png) Execute Approved action Image: FV-Lock module icon (https://fire-vault.com/assets/lock-icon-UU3vOaKE.png) Lock Named access DMZ boundary Trust transition OSS callout Off-network detail ### Where each module is deployed, and what it does there. One row per module. Placement on the network, then plain-English purpose at that point. 1. Image: FV-Isolate module icon (https://fire-vault.com/assets/isolate-icon-B9t8fl3o.png) Isolate At every Purdue boundary Each layer sits on its own physical fabric. A compromise in enterprise cannot walk into process control or safety on the strength of a misconfigured rule. 2. Image: FV-Firebreak module icon (https://fire-vault.com/assets/firebreak-icon-7zSCkB1t.png) Firebreak On the L5 to L4 link and the L4 to L3.5 link Firebreak gives the OT team a real hardware off switch on the IT boundary, so a compromise in enterprise cannot ride a live cable into process control. 3. Image: FV-Relay module icon (https://fire-vault.com/assets/relay-icon-CVhJDRO7.png) Relay Inside the L3.5 DMZ Data moves from enterprise into OT through scheduled, defined routes. Nothing streams unattended. 4. Image: FV-Validate module icon (https://fire-vault.com/assets/vault-icon-CD3Pv4ri.png) Validate Inside the L3.5 DMZ Before anything reaches process control, Validate checks its origin, integrity and authority. 5. Image: FV-Transfer module icon (https://fire-vault.com/assets/transfer-icon-DqGa0PQI.png) Transfer Inside the L3.5 DMZ When data has to move across the boundary, Transfer governs how it crosses and where it lands. 6. Image: FV-Execute module icon (https://fire-vault.com/assets/execute-icon-kJl5Gtmk.png) Execute On the L2 to L1 link Pushing a change to a controller holds until the right approval is in place. 7. Image: FV-Lock module icon (https://fire-vault.com/assets/lock-icon-UU3vOaKE.png) Lock On the L1 to SIS link and the SIS to L0 link Safety is the last layer anything reaches. Lock ties that boundary to named operators with the right engineering authority. Featured In Read about Firevault on TechRadar Pro: https://www.techradar.com/pro/uk-startup-put-physical-disconnect-switch-in-its-cloud-storage-offering-to-mitigate-ransomware-attacks-but-will-that-be-enough Read about Firevault on Yahoo Finance: https://uk.finance.yahoo.com/news/firevault-launches-help-businesses-directors-074500961.html Read about Firevault on Channel Insider: https://www.channelinsider.com/security/tools-and-platforms/firevault-security-offline-platform-offering/ Read about Firevault on Security Buyer: https://securitybuyer.com/uk-cybersecurity-startup-launches-firevault/ Read about Firevault on SecurityBrief: https://securitybrief.com.au/story/firevault-unveils-offline-digital-vault-to-combat-rising-cyber-risks Capabilities ## What you get with every deployment 01 ### PLC & SCADA Config Protection Golden copies of PLC programs, SCADA configurations, and HMI settings stored in hardware-encrypted offline vaults, immune to network-based attacks. 02 ### Historian Backup Process historian data protected in physically disconnected storage, ensuring operational records survive ransomware and are available for safety investigations. 03 ### Controlled Maintenance Windows Time-bound access windows for firmware updates and configuration changes, physical paths open only during authorised periods with full audit trails. 04 ### IEC 62443 Evidence Automated compliance logging maps to IEC 62443 zone and conduit requirements, demonstrable physical separation, not just logical segmentation. 05 ### Zero-Downtime Deployment Deploys alongside existing OT infrastructure without requiring changes to PLCs, SCADA systems, or network architecture, no production disruption. Demo to Live ## Adoption Guide Step 1 #### OT Environment Audit Map all IT/OT boundaries, shared network paths, historian connections, and remote access points to identify where physical separation is required. Step 2 #### Zone and Conduit Design Align Control modules to IEC 62443 security zones and conduits, designing physical separation that maps directly to your compliance requirements. Step 3 #### Non-Disruptive Pilot Deploy alongside existing PLCs, SCADA systems, and RTUs without any changes to operational equipment, zero production downtime during validation. Step 4 #### Production Go-Live Activate controlled maintenance windows, historian backup replication, and immutable audit trails across your entire OT environment. Step 1 #### OT Environment Audit Step 2 #### Zone and Conduit Design Step 3 #### Non-Disruptive Pilot Step 4 #### Production Go-Live Organise a Demo: https://fire-vault.com/contact ## Explore More ### Control for Critical Infrastructure National-grade security for essential services. Learn more about Control for Critical Infrastructure https://fire-vault.com/control-for-critical-infrastructure ### Control for IT Networks Policy-enforced path control across IT infrastructure. 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