Secure OPC Data Replication Using Owl Data Diodes
Overview
This case study showcases the implementation of a secure OPC data replication solution using Owl Cyber Defense data diodes. Designed for high-security environments such as critical infrastructure, the solution leverages Owl’s unidirectional technology to enable safe, real-time, and historical data transfer between OT (Operational Technology) and IT networks. It supports multiple OPC standards, including OPC UA, OPC DA, OPC HDA, and OPC A&E, providing comprehensive operational and business capabilities.
Client Profile
- Industry: Oil & Gas (Upstream Operations)
- Location: Middle East
Challenge
The client needed a secure method to replicate real-time, historical, and event-based data from OPC servers on their isolated OT network to their IT network for analytics, reporting, and decision-making. The solution had to maintain strict network segregation, support various OPC standards, and ensure compliance with cybersecurity regulations such as IEC 62443 and NERC CIP.
Solution
An OPC replication solution was implemented using unidirectional data transfer to:
- Safeguard the OT network from external cyber threats.
- Enable replication of OPC data for analytics and monitoring.
- Ensure compliance with regulatory frameworks.
- Support multiple OPC protocols:
- OPC UA: Platform-independent, secure communication for real-time and historical data.
- OPC DA: Real-time data exchange for SCADA and PLC systems.
- OPC HDA: Historical data retrieval for trend analysis and compliance reporting.
- OPC A&E: Alarms and events monitoring for operational awareness.
Solution Components
- Primary OPC Servers (OT Network):
- Hosted critical operational data via OPC UA, OPC DA, and OPC HDA.
- Processed alarms and events using OPC A&E.
- Owl Data Diode:
- A hardware-enforced unidirectional gateway ensuring outbound-only data flow from OT to IT networks.
- Guaranteed data confidentiality and eliminated cyber threats from IT-side networks.
- Replication Middleware:
- Software that extracts, processes, and securely transmits historical data streams.
- Aggregates alarms and events for actionable insights on the IT side.
- Replica OPC Servers (IT Network):
- Synchronized replicas enabled real-time analytics, historical trend analysis, and incident response monitoring.
- IT-side applications accessed data seamlessly through dashboards.
Key Benefits
- Unmatched Security:
- Owl’s hardware-enforced unidirectional data flow eliminated the risk of cyberattacks propagating from IT to OT networks.
- Versatile Data Support:
- Supported real-time, historical, and event-based data across multiple OPC protocols, ensuring compatibility with diverse systems.
- Regulatory Compliance:
- The solution adhered to industry standards and regulatory requirements.
- Future-Ready Architecture:
- Supported modern IIoT use cases with OPC UA Pub/Sub, enabling high-speed data streams for predictive maintenance and advanced analytics.
- Reliable Data Access:
- Business units accessed operational data for decision-making without compromising OT security.
- Scalable Solution:
- The architecture accommodated legacy systems and modern IIoT implementations, ensuring long-term usability.
- Operational Insights:
- Provided actionable insights from alarms, events, and real-time data, improving decision-making and operational efficiency.
The implementation of OPC replication using Owl data diodes provided the client with a secure, reliable, and scalable solution to access real-time, historical, and event-based data from their OT network. By supporting multiple OPC standards, the solution empowered operational analytics, regulatory compliance, and business intelligence while maintaining strict network segregation. Owl Cyber Defense’s robust technology ensured the client achieved its security and operational goals in a high-assurance environment.
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