Project Brief

Multi-Site OT Cybersecurity Assessment

Specialty Chemicals, Manufacturing


  • The Challenge

The client sought to gain deeper visibility and control across multiple industrial facilities. While each facility had its own systems and processes in place, there was a clear opportunity to enhance standardization, improve documentation, and align cybersecurity practices across the broader OT environment.

Key focus areas included:

  • Establishing a consistent view of OT assets across all facilities
  • Improving clarity around existing network architectures
  • Identifying opportunities to strengthen and unify cybersecurity policies and controls

With this assessment, the client aimed to lay a stronger foundation for long-term resilience and scalable security management.

  • Our Solution
Asset Inventory and Lifecycle Analysis

Champion conducted a thorough inventory of OT assets across all sites, capturing:

  • Detailed information such as make, model, and operational condition
  • Lifecycle stage and support status
  • Physical location and criticality
Network Topology Mapping

We mapped each site’s Process Control Network (PCN), delivering:

  • Accurate, facility-specific network diagrams
  • Visibility into asset interconnectivity and data flow
  • Identification of segmentation gaps and vulnerability points
OT Cybersecurity Gap Assessment and Remediation Planning

Our team performed an in-depth gap analysis and developed a tailored remediation strategy. Key deliverables included:

  • A prioritized list of findings ranked by criticality and operational risk
  • High-level cost estimates for remediation at each facility
  • A strategic roadmap aligned with NIST CSF and industry best practices
  • Project Timeline

4 Months

  • The Results

Champion provided a comprehensive view of the client’s multi-site OT environment, highlighting both areas of strength and opportunities for improvement. Results included:

  • Detailed documentation of assets and network architecture
  • Clear recommendations to formalize cybersecurity policies and procedures
  • Actionable improvements to strengthen monitoring, analytics, and system defenses

We also mapped the client’s position within the NIST Cybersecurity Framework maturity model and delivered prioritized, cost-estimated recommendations. This enabled the client to confidently invest in the most impactful improvements and advance their OT cybersecurity program with clarity and direction.

  • The Champion Advantage
OT Application Expertise

Champion brings deep expertise of both operational technology (OT) environments and enterprise-level network architectures. Our team bridges the IT/OT knowledge gap by:

  • Applying strategies that align with enterprise-wide policies while addressing the unique challenges of OT environments
  • Combining technical depth with hands-on operational experience to reduce risk and improve system resilience
Optimized Integration

Whether upgrading legacy platforms or implementing new technologies, Champion delivers seamless, cost-effective integration. Our proven approach ensures:

  • Interoperability across modern and legacy systems with support for multi-vendor environments

  • Minimal operational disruption through careful planning and phased execution

  • Sustainable, scalable solutions that deliver long-term value and adaptability

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A Guide to Cybersecurity Assessments

Industrial Data Centers: Digital Foundation to Drive Innovation

The Imperative of Proactive Assessments

As industrial environments evolve and IT-OT convergence accelerates, the need for robust cybersecurity grows more urgent. For organizations managing ICS, SCADA, PLCs, and other operational technologies, a compromised system can halt production, endanger safety, and result in regulatory penalties.

Think of cybersecurity assessments as proactive health checks for your control systems. No single test can capture the full picture, each assessment reveals a unique dimension of your cyber risk. When integrated, these assessments form a layered approach that strengthens resilience and guides continuous improvement.

Let’s explore the key assessment types, beginning with the most foundational: the Gap Assessment.

1. Gap Assessment

Gap assessments compare your current cybersecurity state to a defined target, such as regulatory frameworks, industry standards, or internal security policies, to identify specific areas of improvement.

📋Key Components

  • Baseline Evaluation – Establishes the current technical and procedural posture.
  • Target Definition – Defines the expected or required state (e.g., NIST CSF, IEC 62443).
  • Gap Identification – Pinpoints missing controls, insufficient practices, or misaligned documentation.
  • Remediation Planning – Outlines concrete steps to close the gaps.

💡Key Takeaway

Gap assessments are the starting point for any effective cybersecurity improvement plan, revealing exactly what needs to change and helping prioritize remediation.

2. ICS Risk Assessment

This foundational assessment identifies and evaluates risks across your OT environment. It focuses on potential threats, existing vulnerabilities, and the business impact of a successful cyberattack.

📋Key Components

  • Asset Identification – Cataloging ICS components (PLCs, RTUs, HMI, SCADA).
  • Threat Identification – Profiling external and internal threat actors.
  • Vulnerability Discovery – Spotting gaps in systems, processes, and configurations.
  • Impact Analysis – Estimating operational, safety, and financial consequences.
  • Risk Prioritization – Ranking risks to guide mitigation efforts effectively.

💡Key Takeaway

Provides a strategic roadmap to prioritize cybersecurity investments and close high-impact gaps.

3. Vulnerability Assessment

A vulnerability assessment systematically identifies weaknesses, both technical and physical, across your OT environment. It focuses on discovering flaws that could be exploited by threat actors, whether through software vulnerabilities or on-site security gaps.

🔧Key Components

  • Automated Scanning – Identifies known technical vulnerabilities in software, firmware, and network configurations (e.g., unpatched systems, default credentials).
  • Manual Review – Expert analysis of configurations, network architecture, and system documentation to uncover issues not flagged by automated tools.
  • Physical Security Inspection – Assesses physical vulnerabilities such as:
    • Unsecured or poorly located control panels and field devices
    • Inadequate facility access controls (e.g., badge systems, door locks)
    • Lack of surveillance or intrusion detection in critical zones
    • Exposure to environmental hazards (e.g., dust, moisture, vibration)
  • Reporting – Comprehensive documentation of all identified vulnerabilities, including severity ratings and prioritized remediation steps.

💡Key Takeaway

By identifying both cyber and physical weaknesses, this assessment enables a holistic approach to reducing the attack surface and improving overall OT system integrity.

4. Penetration Testing (Pen Testing)

Simulates real-world attacks to uncover exploitable weaknesses and test the efficacy of defenses.

⚠️Note: OT pen testing must be carefully scoped and is often conducted in lab environments or during maintenance windows to avoid disruption.

Pen Test Types

  • Black Box – Simulates an external attacker with no prior access.
  • White Box – Emulates an insider with full system knowledge.
  • Grey Box – Mimics a partially informed attacker.

🔧Key Components

  • Controlled Exploitation – Validates vulnerabilities without disrupting operations.
  • Lateral Movement Analysis – Identifies possible attack paths within your network.
  • Comprehensive Reporting – Details exploitation paths and remediation priorities.

💡Key Takeaway

Pen tests validate real-world defenses and identify weaknesses that could lead to operational compromise.

5. Compliance Assessment

Evaluates your adherence to industry standards and regulations such as ISA/IEC 62443, NIST CSF, or NERC CIP.

📋Key Components

  • Policy & Documentation Review – Assesses alignment with standards.
  • Technical Control Evaluation – Verifies implementation of security measures.
  • Regulatory Gap Identification – Detects compliance shortfalls.

💡Key Takeaway

Supports regulatory alignment, audit readiness, and stakeholder confidence.

6. Cybersecurity Maturity Assessment

Benchmarks your cybersecurity program against recognized maturity models and identifies paths for structured development.

📋Key Components

  • Process & Capability Evaluation – Across risk management, incident response, access control, etc.
  • Benchmarking – Against industry best practices or target maturity levels.
  • Improvement Roadmap – Tailored actions to elevate cybersecurity posture over time.

💡Key Takeaway

Enables strategic program growth by identifying long-term opportunities for maturing security practices.

🧭Choosing the Right Assessment(s)

There’s no one-size-fits-all approach. The right mix of assessments depends on your industry, operational risks, regulatory exposure, and current maturity level. The most effective organizations adopt a cyclical approach, assess, remediate, improve, and reassess.

🛡️The Champion Advantage

Champion combines deep OT expertise with proven cybersecurity practices. We tailor each assessment to your operational reality, ensuring recommendations are actionable, scalable, and aligned with your long-term goals. Our comprehensive approach uncovers risks that others miss and delivers practical solutions that enhance operational resilience.

👉Get Started

Ready to evaluate your OT cybersecurity posture? Understanding the types of assessments is the first step. Let Champion guide you from insight to action, ensuring your systems remain secure, compliant, and future-ready.


Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we'll be there every step of the way.

Let's collaborate.

Schedule a no-cost consultation today.



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From Insight to Action: Unified OT Cybersecurity

Industrial Data Centers: Digital Foundation to Drive Innovation

The OT Cybersecurity Gap: Assessors vs. Remediators

In industrial operational technology (OT), cybersecurity is not a one-time checklist, it’s a continuous necessity. For organizations in critical infrastructure, the journey usually begins with a cybersecurity assessment to identify vulnerabilities and risks.

But here’s the challenge: remediation is often handed off to a different vendor. This separation can slow response times, create confusion, and leave your OT environment exposed.

Why should one partner do both?

Because the most effective cybersecurity isn’t siloed, it’s integrated. Aligning assessment and remediation under one expert team reduces friction and delivers faster, smarter protection.

Bridging the Assessment–Remediation Divide

Engaging separate entities creates unnecessary risk and inefficiency:

  • Interpretation Gaps: What one team flags, another may downplay or miss entirely, especially in OT-specific systems.
  • Delays & Handoffs: Repeatedly explaining your network wastes precious time.
  • Accountability Issues: When fixes fail, finger-pointing often replaces ownership.
  • Context Loss: Remediators who weren’t part of the assessment lack critical insights about your systems and operations.

The Value of a Unified OT Cyber Partner

1. One Team, One Strategy

With one team guiding the process from discovery to fix, you gain:

  • Clear Alignment: Solutions designed by the same people who will implement them.
  • Reduced Miscommunication: No reinterpreting risk reports.
  • End-to-End Accountability: One partner owns the outcome.

2. Faster Time to Protection

Speed matters. With a unified team:

  • No Learning Curve: Immediate action based on firsthand knowledge.
  • Direct Communication: Faster decisions, fewer delays.
  • Less Downtime: Solutions executed with full awareness of operational constraints.

3. Cost-Efficient, Targeted Remediation

Better context equals smarter fixes:

  • Precision: Fixes are relevant and necessary, no wasted effort.
  • Fewer Errors: Eliminates rework from misaligned expectations.
  • Stronger ROI: Rapid risk reduction lowers potential incident costs.

4. A Long-Term Cybersecurity Ally

Beyond just projects, a combined approach builds a partnership:

  • Ongoing Insight: A team that’s been there before can proactively support future improvements.
  • Trusted Guidance: Consistent support from experts familiar with your people, systems, and risk profile.

The Champion Advantage

Champion Technology isn’t just an OT cybersecurity assessor; we’re your remediation partner too. From risk identification to hands-on resolution, we bring a deep understanding of industrial systems, network security, and operational constraints.
Our approach prioritizes continuity, communication, and cybersecurity without compromise, because in the world of OT, downtime isn’t an option.


Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we'll be there every step of the way.

Let's collaborate.

Schedule a no-cost consultation today.



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CISA’s Guide to OT Network Segmentation

Industrial Data Centers: Digital Foundation to Drive Innovation

🛡️Why Network Segmentation Matters

Network segmentation is a cornerstone of OT cybersecurity. It involves dividing a network into isolated, secure zones—either physically or virtually—each acting as a self-contained subnetwork. This approach:

  • Reduces risk
  • Enhances control
  • Prevents lateral movement in the event of a breach

The Cybersecurity and Infrastructure Security Agency (CISA) emphasizes the importance of segmentation and provides a clear, actionable framework for its implementation—especially for critical infrastructure environments.

Top 5 Benefits of Network Segmentation

  1. Threat Containment: Compromised systems are confined within their segment, preventing wider disruption.
  2. Smaller Attack Surface: Limiting inter-zone communication reduces paths for attackers to reach sensitive assets.
  3. Protection of Critical Assets: High-value systems like DCSs, PLCs, HMIs, and control servers are isolated from less secure IT zones.
  4. Improved Monitoring: Smaller zones allow for more precise anomaly detection and event tracking.
  5. Compliance Enablement: Helps meet requirements in frameworks like ISA/IEC 62443, which mandate segmentation as a baseline control.

Key Components of an Effective Segmentation Strategy

1. Define and Group Zones

Organize assets by function and risk level. Typical OT zones include:

  • Control Zone: PLCs, DCS, SCADA, most critical layer.
  • Historian Zone: Operational data aggregation.
  • MES Zone: Operational-to-enterprise handoff.
  • Remote Access Zone: For secure third-party or vendor access.
  • Enterprise IT Zone: Business apps and office systems.

2. Establish Secure Conduits Between Zones

  • Strict Communication Rules: Permit only essential traffic between zones, with defined protocols and endpoints.
  • Firewalls with ACLs: Use industrial firewalls and Access Control Lists to strictly manage inter-zone traffic.
  • DMZ Deployment: A DMZ acts as a secure proxy zone between IT and OT, preventing direct access while enabling controlled data exchange.

What is a Demilitarized Zone (DMZ)?

A secure buffer that separates critical OT systems from external or enterprise networks.

3. Test, Monitor, and Maintain Continuously

  • Validate Controls: Post-deployment testing ensures segmentation functions correctly without disrupting operations.
  • Continuous Monitoring: Track traffic flows and flag deviations or unauthorized access attempts.
  • Ongoing Review: Update policies as new assets or threats arise.

🏆 The Champion Advantage

Effective segmentation requires more than IT knowledge, it demands a deep understanding of industrial processes. That’s where Champion Technology Services excels.

We deliver segmentation strategies that:

  • Protect operations without disrupting uptime
  • Align with CISA guidance and industry specific standards
  • Bridge IT security best practices with OT realities

We combine cybersecurity leadership with control system expertise to design and implement resilient, scalable, and compliant network architectures for critical infrastructure environments.


Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we'll be there every step of the way.

CISA Recommendations

  • Segment high-value assets into isolated, high-security zones.
  • Use firewalls with specific access control rules.
  • Create a DMZ for critical cross-domain operations.
  • Limit access to DMZ devices through defined user and device lists.
  • Restrict data traffic from OT to IT, particularly for remote access.

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Safeguarding Your Expanding OT Assets: Maintaining & Securing IDCs

Industrial Data Centers: Digital Foundation to Drive Innovation

Expanding Footprint, Escalating Complexity: What's Next?

Industrial operational technology (OT) is evolving fast. Once-isolated systems now rely on interconnected virtual machines, edge devices, software agents, and cloud connectors. At the center of this transformation sits the Industrial Data Center (IDC), the control hub for real-time operations, data acquisition, and analytics.

But with greater digitalization comes a challenge: How do you maintain and secure your IDC in a scalable, reliable, and cost-effective way?

It starts with moving beyond traditional IT approaches and adopting frameworks built specifically for OT environments.

What Makes IDCs Different?

Unlike enterprise data centers, IDCs operate in high-stakes environments where uptime is non-negotiable. A failure isn’t just an IT issue, it can halt production, cause safety incidents, or trigger regulatory violations.

IDCs in critical infrastructure sectors demand special attention in four key areas:

  • Operational Continuity: Real-time control requires zero latency and uninterrupted uptime.
  • System Reliability: All components, hardware and software, must perform predictably.
  • Legacy Integration: OT systems often blend decades-old tech with new platforms.
  • Cyber-Physical Risk: Digital breaches can cause real-world harm.

Three Pillars of IDC Reliability & Security

1. Infrastructure Resilience for OT Uptime

Reliability begins with the physical and virtual backbone of the IDC:

  • Hardware Redundancy: Use failover-ready servers, networks, and storage to eliminate single points of failure.
  • Component Health Monitoring: Proactively monitor CPUs, memory, storage, power, and network performance to identify issues before they impact operations.

2. Cybersecurity Built for Converged OT/IT Environments

Cyber threats don’t stop at the firewall and in OT, they can be catastrophic:

  • Network Segmentation: Isolate OT networks (e.g., control, historian) to contain breaches and reduce risk.
  • Patch Management: Develop OT-specific strategies that prioritize safety, vendor compatibility, and availability.
  • Endpoint Security: Secure all IDC assets, servers, workstations, devices, with antivirus, firewalls, and intrusion detection.
  • IAM & Remote Access Control: Enforce least-privilege, MFA, and regular access audits.
  • Vulnerability Management: Continuously assess and remediate weaknesses in software, firmware, and configurations.

3. Proactive Monitoring & Lifecycle Governance

Resilient systems don’t just react, they anticipate:

The Champion Advantage

For organizations modernizing their OT backbone, Champion Technology Services offers deep experience in building and securing IDCs in high-risk industrial sectors. From hazardous midstream operations to specialty chemical plants, we deliver:

  • Turnkey Infrastructure Solutions— From power and cooling to server and storage design
  • Secure Network Architectures— Segmented, fault-tolerant, and built for OT
  • Integrated Cybersecurity Controls— Aligned with industry standards like ISA/IEC 62443
  • Lifecycle & Modernization Planning— Keeping your systems future-ready

Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we'll be there every step of the way.

Let's collaborate.

Schedule a no-cost consultation today.



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Scalable Strategies for OT Asset Management in a Growing Digital Landscape

Industrial Data Centers: Digital Foundation to Drive Innovation

More Assets, More Complexity, Now What?

Industrial operations today are not just adding hardware, they’re layering in virtual machines, edge devices, software agents, and cloud connectors. With this growth comes the challenge: how do you manage all these assets reliably, securely, and cost-effectively at scale?

The answer lies in combining monitoring with structured asset management strategies.

Strategy 1: Establish a Baseline with Passive Discovery

Before you can manage, you need visibility.

  • Start with Passive Monitoring tools to automatically detect devices communicating across your network. 
  • Build an initial asset inventory that includes IP, MAC, vendor, model, and firmware.
  • Capture not just what’s online, but what’s vulnerable, misconfigured, or behaving abnormally. 

Tip

Passive monitoring can often be deployed with zero impact to operations and works across diverse platforms.

Strategy 2: Tag & Contextualize Assets 

An inventory without context is just a list.

  • Tag assets with critical metadata—such as control zone, site, function (e.g., HMI,DCS, historian), and ownership. 
  • Link this data with existing sources: CMMS, control system configuration, historian, or network diagrams.
  • Use human-friendly naming conventions and hierarchy to support operational handoffs and audits. 

PRACTICAL STEP

Use spreadsheet imports, CMDB tools, or open API integrations to enrich your inventory without manual re-entry.

Strategy 3: Integrate Monitoring with Lifecycle Planning 

Monitoring tells you what’s happening—asset management tells you what to do next.

  • Leverage performance data to flag aging or underperforming assets.
  • Track lifecycle stages: install date, firmware version, last patch, end-of-support.
  • Schedule reviews for high-risk systems or those approaching obsolescence.

bonus

If you’ve recently migrated to a modern system, start lifecycle tracking from day one to maximize ROI.

Strategy 4: Build Change Management into Daily Operations

Static inventories go stale fast.

  • Monitor for unauthorized changes in firmware, configuration, or IP address.
  • Tie changes to maintenance work orders or authorized updates.
  • Use alerts to notify engineering or cybersecurity teams when anomalies occur.

Scalable Tactic

Focus on key control zones first, then expand visibility zone by zone, prioritize based on risk and asset count.

Strategy 5: Make It Actionable for the Teams Who Need It

The most successful OT asset strategies are ones that are used daily.

  • Build dashboards that serve operators, not just auditors.
  • Align asset groups with how your team works, by process area, shift, or system owner.
  • Offer read-only access to contractors or support teams to eliminate bottlenecks.

TOOLTIP

Integrate with your existing FAT documentation, virtual environments, or support models like our 24UP® Solution, to make data available in context.

Conclusion: OT Asset Management is a Discipline, Not a Project

Scalability doesn’t come from a one-time cleanup, it comes from embedding asset practices into monitoring, maintenance, and modernization. Whether you’re managing 100 devices or 10,000, the right strategy allows your team to grow confidently alongside your infrastructure.


Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we'll be there every step of the way.

Let's collaborate.

Schedule a no-cost consultation today.



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Asset Management


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Mastering OT Asset Monitoring

June 12, 2025

Mastering OT Asset Monitoring

Asset Monitoring, Operational Technology

Leverage passive, active, and predictive monitoring to unlock reliability, security, and performance in modern OT environments.

Industrial Data Centers: Digital Foundation to Drive Innovation

🛠️Optimizing Uptime Through OT Monitoring

As industrial OT systems modernize and become more interconnected, the potential for efficiency and insight grows, but so do complexity and cybersecurity risk. To navigate this landscape, organizations must move beyond reactive maintenance and adopt a layered, proactive monitoring strategy.

🔍Three Pillars of Modern OT Monitoring

Just as a skilled technician uses multiple tools to assess a system, a modern OT monitoring strategy relies on three complementary methods: passive, active, and predictive. When combined, they create a robust defense and operational advantage.

Passive Monitoring

The Silent Observer of OT Health

Passive monitoring silently collects data from systems without direct interaction. It captures the “background noise” of OT—CPU usage, network traffic, system logs—offering insights without introducing risk.

Use Cases:

  • Baseline Behavior: Define normal operating parameters to detect future anomalies.
  • Capacity Forecasting: Plan infrastructure scaling based on usage trends.
  • Performance Trends: Spot degradation or irregularities early.
  • Asset Visibility: Maintain a real-time inventory of connected OT assets.

Active Monitoring

Probing for Responsiveness and Resilience

Active monitoring takes a deliberate, hands-on approach. By sending test traffic or running diagnostics, it probes systems to detect weaknesses or performance bottlenecks.

Use Cases:

  • Early Issue Detection: Identify misconfigurations or failing components.
  • Network & Application Tuning: Support digital initiatives with optimized performance.
  • Cyber Vulnerability Scanning: Detect threats across newly connected assets.
  • Regulatory Readiness: Validate compliance with industry standards.

Predictive Monitoring

Anticipating What’s Next

Predictive monitoring applies analytics and machine learning to historical and real-time data to forecast problems before they occur.

Use Cases:

  • Predictive Maintenance: Anticipate equipment failures and plan service proactively.
  • Resource Planning: Forecast compute and bandwidth needs as systems scale.
  • Anomaly Detection: Flag unusual activity that could signal cyber threats.
  • Downtime Reduction: Improve system uptime and reliability through foresight.

⚖️Why the Blend Matters

Each technique brings value, but together they form a resilient and intelligent monitoring ecosystem:

  • Passive reveals system norms and long-term trends.
  • Active exposes immediate issues and security gaps.
  • Predictive enables preemptive action to avoid disruptions.

Conclusion

In a digital-first OT landscape, monitoring must evolve. A layered strategy, passive for visibility, active for control, and predictive for foresight, empowers industrial organizations to maintain uptime, ensure security, and drive operational excellence. It’s not just about watching your systems; it’s about truly understanding them.

Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we’ll be there every step of the way.

Let’s collaborate.

Schedule a no-cost consultation today.

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Factory Acceptance Testing: A Critical Step to De-Risk Control System Deployments

Industrial Data Centers: Digital Foundation to Drive Innovation

Why Factory Acceptance Testing Matters in Control System Projects🎯 

In the high-stakes world of industrial automation, Factory Acceptance Testing (FAT) is far more than a formality, it's a critical milestone that validates system functionality before it ever reaches the field.

For control systems and OT solutions, FAT provides a structured, repeatable environment to detect logic errors, integration issues, and design gaps, well before they can disrupt operations.

Champion’s Edge: Infrastructure and Expertise That De-Risk FAT 🔧

At Champion, we don’t just conduct FAT, we engineer it for success.

Our in-house simulation environments are equipped with:

  • Vendor-specific control hardware
  • Test racks and I/O simulators
  • Pre-configured operator workstations

This setup enables us to replicate real-world conditions and rigorously test each component—whether it’s Honeywell Experion®, Rockwell Automation, Emerson DeltaV, or hybrid environments.

With deep OT domain knowledge and integrated testing infrastructure, we ensure your system performs as expected—under load, under pressure, and under control.

Top 5 Reasons FAT Reduces Project Risk ✅

1. Catch Issues Before They Reach the Field

Our controlled test environments uncover misconfigurations, logic errors, and network issues long before on-site commissioning, saving time, cost, and operational downtime.

2. Validate Functional Design and Logic

From PLC code and HMI graphics to alarm management and SCADA point validation, Champion helps clients confirm that their system meets all functional specifications before deployment.

3. Boost Operator Confidence Through Simulation

Our FAT process includes realistic operator interaction using actual graphics, navigation workflows, and input/output simulations, helping users gain familiarity and confidence before go-live.

4. Strengthen Cybersecurity and Network Assurance

FAT also enables testing of industrial network solutions, Windows domain configurations, and role-based access controls to ensure secure, reliable system performance.

5. Support a Low-Risk, Structured Commissioning Phase

With Champion’s FAT preparation and documentation, commissioning becomes a controlled process, not a troubleshooting exercise.

Best Practices for Effective FAT Execution📋

  • Start Early
    Plan for FAT in your initial project scope and timeline.
  • Test What Matters
    Simulate realistic operations, not just scripted tests.

  • Involve the Right People
    Engage operations, cybersecurity, and IT stakeholders throughout the process.

  • Document and Sign Off
    Capture results, track issues, and create a clear FAT record.

  • Close the Loop
    Use insights from FAT to fine-tune configuration and commissioning.

🏅The Champion Difference: More Than a Checklist

FAT is your system’s first big test, and Champion ensures it’s a real one.

Our investment in simulation hardware, OT software environments, and seasoned engineering teams means we don’t just verify your system, we optimize it, harden it, and prepare it for day-one success


Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we'll be there every step of the way.

Let's collaborate.

Schedule a no-cost consultation today.



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Project Brief

PCN and DMZ IDC Upgrade

Petrochemicals, Manufacturing // Louisiana


  • The Challenge
Outdated Virtual Environments

Existing datacenter hardware had reached end-of-life, creating limitations in performance, maintainability, and vendor support.

Unscalable System Architecture

The legacy PCN and DMZ systems were built on unupgradable physical appliances, unable to support growing demands or modern applications.

Minimal Redundancy and Recovery

The prior environment lacked virtualization-level failover, reducing the ability to maintain continuity during failures or maintenance.

Unsupported OS and Applications

Critical virtual machines were operating on unsupported platforms, limiting cybersecurity alignment and software patching options.

Mixed Configuration and Oversight

Disparate domain structures and unmanaged system updates posed obstacles to centralized control and consistent operations.

Zero-Disruption Requirement

Upgrades had to be completed without interrupting plant operations, requiring parallel validation and a risk-informed deployment plan.

  • Our Solution
Virtual Infrastructure Modernization

High-availability PCN clusters and standalone DMZ servers were implemented using ESXi hosts and Dell storage arrays, managed via vCenter.

Network Architecture Redesign

Cisco Catalyst switches provided redundant paths, VLAN segmentation, and firewall integration to enhance reliability and zone isolation.

Factory Acceptance & Site Testing

In-house FAT and site SAT validated configuration and failover. Cutover was completed with zero operational impact.

VM and Software Configuration

Over 20 virtual machines were configured to support:

  • Real-time industrial data collection and historian interfaces
  • Antivirus and centralized patching services
  • Rotating equipment condition monitoring and diagnostics software
  • Control system trace and event logging tools
  • Active Directory domain control and backup systems
  • Project Timeline: 8 Months
  • The Results
Improved Uptime

Cluster failover and HA ensure operational continuity and quick recovery.

Stronger Cybersecurity Posture

Supported OS versions, AV/patching agents, and segmented VLANs align with OT best practices.

Streamlined Management

Domain integration, backup validation, and centralized vCenter simplify operations and updates.

Scalable Architecture

The system is designed for future expansion, remote diagnostics, and lifecycle planning.

  • The Champion Advantage
Seamless Integration

Champion delivered a unified virtual infrastructure, covering computer, networking, and virtualization, with end-to-end accountability from design through commissioning.

Client-Centered Execution and Support

From risk-informed cutover strategies to on-site support, Champion aligned closely with operational constraints to execute without disruption to any critical processes.

Future-Ready Foundation

The virtual architecture supports future growth, secure access, centralized patching, and improved OT visibility, positioning the client for ongoing digital transformation.

OT Application Expertise

With deep experience in OT Applications such as historian integration, rotating asset diagnostics, trace/event logging, and OT endpoint security, Champion ensured each application was migrated, validated, and optimized in the new environment.

Smarter Commissioning, Faster Execution

Champion’s structured FAT, SAT, and operator validation approach delivered efficient deployment with confidence in operational readiness.

Curious what Champion can achieve for you?


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Virtualizing the Future

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Industrial Data Centers: Digital Foundation to Drive Innovation

Powering OT Digital Transformation: Virtualization in IDCs

The push for Digital Transformation is reshaping Industrial Operational Technology (OT). It demands greater connectivity, data utilization, and agility. At the center of this evolution is virtualization, and when deployed within a robust Industrial Data Center (IDC), it becomes the foundation for a smarter, more resilient OT environment.

From Siloed Hardware to Agile Infrastructure

Traditionally, OT systems relied on purpose-built physical hardware. This siloed approach, while once effective, now limits integration and scalability. Virtualization, creating software-based versions of computing resources, solves this challenge.

When hosted in an IDC, virtualization consolidates OT applications and even control system components onto shared physical hardware, delivering a more dynamic and manageable environment.

The IDC Advantage: A Foundation for Virtualized OT

Industrial Data Centers are more than server racks. They are mission-critical environments purpose-built to support the demands of virtualized OT systems:

  • Reliable Power & Cooling – Keeps systems running smoothly under consolidated loads.
  • High-Speed Networking – Enables low-latency communication across virtual and physical assets.
  • Security by Design – Protects both virtual and physical layers of OT infrastructure.
  • Scalability & Redundancy – Supports growth while ensuring uptime.

Virtualization: The Engine of OT Modernization

Virtualization within an IDC unlocks new capabilities:

  • Agility and Rapid Deployment
    Provision new OT environments quickly—no waiting on hardware delivery or installation.
  • Resource Optimization
    Run multiple OT applications on fewer physical servers, saving energy, floor space, and costs.
  • Centralized Management
    Streamline backups, patching, disaster recovery, and monitoring—all from a single pane of glass.
  • High Availability and Resilience
    Virtual workloads can move between servers with zero downtime using live migration and fault tolerance.
  • Secure Integration
    Enable safe, structured data sharing between OT and IT systems for analytics and enterprise insight.

Strategic Considerations for Virtualizing OT in an IDC

Successfully deploying virtualization in an IDC requires thoughtful planning:

  • Workload Suitability – Not all OT workloads are ideal for virtualization. Prioritize based on performance and latency sensitivity.
  • IDC Readiness – Ensure the data center has the power, cooling, and connectivity to support virtualized workloads.
  • Virtualization Platform – Choose a platform with industrial certifications and robust support for OT systems.
  • Network Segmentation – Properly isolate OT systems to maintain security and regulatory compliance.
  • Expertise and Integration – Work with partners like Champion Technology, who understand both OT requirements and data center architecture.

Looking Ahead: OT’s Virtual Future

The combination of virtualization and Industrial Data Centers is rapidly becoming the backbone of future-ready OT operations. It enables organizations to:

  • Modernize aging infrastructure
  • Enhance security and availability
  • Reduce physical and energy footprints
  • Accelerate time-to-insight through data integration

As industrial environments grow more connected and data-driven, embracing this strategic shift isn’t optional—it’s imperative.

Our team helps OT leaders modernize with confidence. Our expertise in virtualized infrastructure and control system environments makes us a trusted partner for your Digital Transformation journey.


Ready to learn more? Contact us today to schedule a no-cost consultation.

We empower our clients to build safe, sustainable operations by delivering comprehensive Operational Technology (OT) solutions. From concept to implementation and beyond– we'll be there every step of the way.

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