Client Overview: Our client is a leading power plant company in India, operating 50 plants spread across the country. These plants play a pivotal role in supplying electricity to millions of citizens and businesses in various cities and states. Given the critical nature of their infrastructure and the importance of uninterrupted power supply, securing their operations is a top priority.
The client approached us with a unique challenge: to develop a Security Operations Center (SOC) for their Operational Technology (OT) environment. OT systems control and monitor physical processes in the power plants, making them highly sensitive and crucial for the safe and efficient functioning of the plants. However, OT environments are often vulnerable to cyber threats due to their inherent connectivity to industrial systems and devices, and the client wanted to ensure these systems were not exposed to external risks while maintaining operational efficiency.
The challenge was compounded by budget constraints, which meant we had to design an efficient, cost-effective solution that could safeguard their OT systems without sacrificing performance or security.
Challenge: The client’s OT environment posed several specific challenges:
- Segregation of IT and OT Networks: The OT environment was physically separated from the IT infrastructure, with firewalls and switches in place to prevent direct communication between the two. However, this segmentation had limitations, and additional security measures were needed to ensure OT devices were not exposed to the internet or other external threats.
- Exposing OT to the Internet: OT systems are highly sensitive and should never be directly exposed to the internet, as this could lead to catastrophic security breaches, such as remote access to critical infrastructure, system manipulation, or even physical damage to the plants.
- Independent Operation of OT Plants: Each of the client’s 50 plants was operating independently, with no centralized monitoring of the OT network. This decentralized setup made it challenging to ensure comprehensive security monitoring across all sites.
- Budget Constraints: The client wanted to implement a robust security architecture but was constrained by a limited budget, meaning cost-effective solutions had to be prioritized without compromising on the integrity of the OT security.
Scope: Designing a Secure OT Network Infrastructure + Security Operations Center (SOC)
Engagement Overview
Given the sensitivity and complexity of the OT environment, we developed a tailored strategy to establish a secure SOC for the client. Our approach focused on segmentation, secure communication, and real-time monitoring, while keeping the client’s budgetary limitations in mind.
1. Understanding the Requirements and Network Infrastructure
We began by conducting a thorough assessment of the client’s existing infrastructure, including their firewalls, switches, and network architecture, to understand how their OT and IT networks were segregated. It was clear that while basic network segmentation existed, the lack of centralized monitoring and the potential exposure of OT systems to the internet posed significant risks.
2. Establishing a DMZ for the OT Network
The first step in securing the OT environment was to create a Demilitarized Zone (DMZ) between the OT network. The DMZ would act as a secure buffer zone to ensure that OT devices were isolated from any direct internet exposure. This architecture ensured that no critical OT systems could be directly accessed from outside the secure network.
We also deployed a secure OT Gateway, providing controlled access to the OT systems without exposing them to external threats. This gateway served as a secure entry point for any authorized users or services that needed to interact with the OT systems.
3. Installing SIEM and Log Aggregator for Monitoring
We implemented a Security Information and Event Management (SIEM) system and a log aggregator. This allowed us to collect logs from various OT devices across all plants. The logs were then analyzed for any suspicious activity or signs of cyber threats, providing real-time insight into the health of the OT environment.
4. Deploying IDS/IPS for Threat Detection
Next, we installed Intrusion Detection Systems (IDS) and Intrusion Prevention Systems (IPS) to actively monitor for any potential intrusions or anomalous behavior. These systems would detect any unauthorized access attempts or malicious traffic, allowing for immediate remediation to prevent threats from escalating.
5. Real-Time Traffic Monitoring with Zabbix and ntopng
To gain further visibility into the network, we deployed Zabbix and ntopng for real-time traffic monitoring. These tools allowed us to track live traffic between OT devices, providing both detailed performance insights and real-time threat detection.
We configured a centralized monitoring dashboard that displayed live traffic data across all 50 plants, giving the client a single, unified view of their OT network’s health and security posture.
6. Overcoming the Independent Operation of OT Plants
The client’s biggest challenge was the independent operation of each plant, which meant that there was no centralized monitoring of the OT network. To address this, we created a central server that connected to all the agents deployed in the individual plants. This central server acted as the hub for collecting data from each of the plant’s OT networks.
However, directly connecting the central server to the plants posed a security risk. To mitigate this, we implemented a Jump Server—an intermediary secure server that facilitated communication between the central server and each plant’s network. This secure connection ensured that no direct links were made between the plant’s OT network and the central server, thus reducing the attack surface.
7. Ensuring Remote Access to the SOC Dashboard
The client expressed a need for remote monitoring of their SOC dashboard, allowing them to oversee the status of their OT environment from a central location, regardless of where their security team was based. Using VPNs and secure login protocols, we set up remote access to the dashboard, ensuring that only authorized personnel could log in and view the critical OT data.
8. Delivering a Secure and Cost-Effective SOC Solution
Despite the budget constraints, our solution met the client’s requirements for a robust SOC architecture. By leveraging tools like Zabbix, ntopng, and Jump Servers, we created a cost-effective yet secure solution that provided comprehensive monitoring, threat detection, and remote access to the client’s OT environment.
Outcome and Conclusion
The final SOC architecture proved to be highly secure and robust, ensuring that the client’s OT systems were effectively isolated from the internet and other networks. By creating a secure DMZ, implementing SIEM, IDS/IPS, and live traffic monitoring, we successfully enhanced the overall security structure of the client’s OT plants.
The centralized monitoring system allowed the client to view all live traffic data from across their 50 plants on a single dashboard, offering real-time visibility into potential threats. Additionally, the Jump Server and secure remote access ensured that only authorized personnel could interact with the SOC dashboard, reducing the risk of unauthorized access.
This engagement not only provided the client with a cost-effective SOC solution but also helped them enhance the security posture of their OT infrastructure, ensuring the safe and uninterrupted operation of their power plants. The client was able to safeguard their critical assets, improve their incident response capabilities, and confidently move forward with their digital transformation efforts.