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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.

Contact an expert

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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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Solution Brief

Industrial Data Centers

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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

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Virtualizing the Future

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.

Let's collaborate.

Schedule a no-cost consultation today.

 Contact an expert
Solution Brief

Industrial Data Centers

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24UP®: Smarter Maintenance for Industrial Control Systems

Industrial Data Centers: Digital Foundation to Drive Innovation

In the world of industrial automation, maintaining uptime isn’t just about fixing issues, it’s about anticipating them. That’s where 24UP®, Champion’s Run and Maintain service, stands apart. Designed to sustain operational continuity and safeguard critical control infrastructure, 24UP delivers more than support, it delivers trust.

Champion brings over two decades of hands-on experience across a broad range of control system platforms, network architectures, and OT environments. From Honeywell Experion and Emerson DeltaV to Rockwell Automation, Schneider Electric, and legacy platforms like Honeywell TDC, Allen-Bradley PLC-5 or Siemens S5/S7, our teams understand the nuances of industrial automation—and how to keep it running.

Why 24UP?

Engineered for Industrial DX Maintenance 🚀

As digital transformation (DX) accelerates across the industrial sector, the volume and complexity of digital OT assets are growing rapidly. From connected field devices and virtualized control systems to cloud-integrated historians and cybersecurity platforms, maintaining these assets requires more than just break/fix support, it demands continuous oversight.

24UP was purpose-built to support this shift. Our service is real-time enabled, delivering actionable insights across both modern and legacy DCS and PLC platforms. Whether you're managing cutting-edge architectures or aging infrastructure, 24UP helps maintain system health, configuration integrity, and operational resilience.

Cybersecurity & Compliance Visibility 🔐

Our enterprise dashboards highlight vulnerabilities, backup status, patching gaps, and hygiene scores—empowering facilities to stay compliant and reduce cyber risk across legacy and modern systems.

Support Backed by Real OT Knowledge 🛠️

Every ticket, escalation, and support event is handled by engineers who’ve stood in front of live DCS panels and PLC racks. From after-hours emergency calls to scheduled turnarounds, you get expert support from people who know the control systems inside out.

Championing Performance. Sustaining Reliability.

We know industrial systems don’t run on theory, they run on execution. With 24UP®, we combine digital tools and decades of operational experience to help clients maintain OT asset health, meet compliance goals, and keep production on track.

Whether you’re managing an aging DCS, navigating cybersecurity modernization, or just need peace of mind, 24UP is your partner in performance.

Let’s talk about how 24UP can work for you. Contact us today to schedule a demo and see why clients in refining, petrochemicals, and energy choose Champion for OT support that actually understands OT.

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.

 Contact an expert
more on our website

24UP® Solutions

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Project Brief

Industrial Data Center Upgrade

Oil & Gas, Midstream // Southeast Texas


  • The Challenge

Legacy data center hardware had reached end-of-life, limiting system reliability, scalability, and vendor support options.

Obsolete Windows environments prevented the application of critical patches and updates, impacting compliance and system stability.

Outdated versions of FactoryTalk and historian software introduced performance bottlenecks and integration challenges with modern platforms.

A fragmented domain and workgroup configuration made it difficult to enforce consistent user policies or manage authentication centrally.

Limited VLAN segmentation reduced network visibility, increased broadcast domain congestion, and created barriers to secure zone management.

The absence of high-availability mechanisms and VM mobility increased risk during maintenance windows and system transitions.

The migration needed to occur without interrupting operations, requiring a carefully sequenced cutover plan and parallel runtime verification.

  • Our Solution

Both data center environments were rebuilt with fully virtualized, high-availability platforms. Core control system applications, historian nodes, and Windows services were migrated to domain-managed virtual machines for greater scalability and centralized control.

Switching infrastructure was upgraded to support segmented VLANs for management, storage, and control traffic. Routed failover between sites provided redundancy and improved network performance.

OT applications including FactoryTalk View SE, Linx, Alarm & Event, and Historian services were upgraded to current versions. Engineering and operator workstations were refreshed with pre-configured toolsets for faster deployment and user readiness.

A structured deployment approach included Factory Acceptance Testing (FAT), parallel HMI validation, and a staged cutover. Snapshot backups and rollback procedures ensured system continuity throughout.

  • Project Timeline: 6 Months
  • The Results

The modernized OT systems delivered key advantages. Redundant systems ensured uptime and operational continuity, while network segmentation and supported platforms strengthened cybersecurity. Centralized control simplified management, and modern infrastructure provided fast recovery and failover.

  • The Champion Advantage
Seamless Integration

A unified solution across virtualization, networking, and software eliminated the need for multiple vendors.

Client-Centered Execution and Support

Staged cutover, clear documentation, and on-site training ensured a smooth transition with minimal disruption.

Scalable and Future-Ready

The upgraded infrastructure supports digital growth, remote access, and enhanced OT visibility.

Smarter Commissioning, Faster Execution

Champion’s risk-informed approach, with FAT, SAT, and operator validation, enabled efficient deployment and handoff.

Ready to elevate your operations?

contact us
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Securing Legacy OT Systems

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Disaster Recovery

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Enhance OT Security with Network Segmentation

Select Dynamic field
In today's increasingly connected operational environments, network segmentation is a foundational pillar for cybersecurity, performance, and system reliability. For industrial facilities managing legacy assets, segmentation isn't just an IT best practice, it's a business-critical strategy.

What is Network Segmentation?

Network segmentation involves dividing a network into smaller, isolated segments (or subnets), each with its own access controls and security measures. This approach:

  • Minimizes the attack surface
  • Restricts lateral movement by threat actors
  • Prevents malware from spreading across the network

6 Key Strategies for Effective Segmentation

1. IT/OT Alignment 🤝

Ensure collaboration between IT and OT teams from the outset. Joint planning, training, and awareness initiatives build shared ownership and improve execution.

2. Identify Critical Assets 🔍

Prioritize protection by identifying which systems are most critical to operations. This enables a phased segmentation approach that minimizes disruption.

3. Network Mapping 🗺️

Visualizing all connected entities reveals data flows, hidden vulnerabilities, and monitoring blind spots—essential for informed segmentation planning.

4. Define Network Zones 🧱

Group systems with similar security requirements into zones, and enforce strict rules for how data moves between them. This zoning model forms the backbone of OT segmentation.

5. Implementation ⚙️

Roll out segmentation in phases to minimize operational risk. Closely monitor performance throughout the rollout to identify and resolve unforeseen issues early.

6. Monitor and Maintain 📈

Ongoing monitoring and regular audits ensure the segmentation strategy adapts to evolving threats. Update protocols and configurations as your network grows or changes.

The Takeaway

As cyber threats grow more sophisticated, network segmentation is no longer optional—it’s foundational. By creating controlled, isolated zones within your OT network, you enhance system protection, simplify compliance, and future-proof your operations for digital transformation.

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.

 Contact an expert
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System Hardening

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End of Support for Windows 10: A Strategic Opportunity for OT Environments

Industrial Data Centers: Digital Foundation to Drive Innovation

What the End of Windows 10 Support Means for OT

On October 14, 2025, Microsoft will officially end support for Windows 10. While this change raises important cybersecurity and compliance concerns, it also presents a chance for industrial and OT facilities to modernize critical infrastructure.

We don’t view this milestone as a disruption, but as a moment to strategically enhance your systems—building resilience, security, and readiness for tomorrow’s demands.

Why Strategic Action Is Essential in OT Environments

Unlike general IT systems, OT environments operate in high-stakes, highly regulated settings. Unsupported systems introduce serious risks—but transitioning with intention offers real, measurable benefits:

🔒 Enhanced Cybersecurity

Upgrading from Windows 10 enables deployment of modern operating systems with advanced security features and ongoing support—significantly reducing your exposure to cyber threats.

⚙️ Infrastructure Built for the Future

New platforms support greater interoperability, performance, and readiness for future digital transformation initiatives.

🚀 Improved Operational Efficiency

Modernized systems contribute to smoother performance, simplified maintenance, and fewer unplanned outages.

✅ Regulatory Compliance

Maintaining supported systems ensures alignment with evolving industry standards—helping avoid penalties and reinforcing your security posture.

How Champion Helps You Transition with Confidence

We deliver vendor-neutral, OT-specific strategies tailored to your unique environment. Our support includes:

🔧 Upgrade Planning & Migration

We develop and execute upgrade roadmaps that minimize disruption and maximize value.

🛡️ OT-Focused Cybersecurity Enhancements

  • Network Segmentation: Designing secure zones for critical systems.
  • Advanced Firewalls: Implementing industrial-grade perimeter defense.
  • Intrusion Detection and Prevention: Real-time threat detection and response.
  • Security Audits: Identifying and remediating vulnerabilities.
  • Cybersecurity Training: Equipping your personnel to be the first line of defense.
  • Incident Response Planning: Ensuring rapid, coordinated action in the event of a breach.

Prepare Today. Lead Tomorrow.

The Windows 10 deadline isn’t the end—it’s the beginning of a more secure, capable, and resilient OT environment. Champion is your trusted partner for navigating this shift with clarity and strength. Let's start planning your transition today.

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.

 Contact an expert
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DCOM Hardening

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Project Brief

On-Process Control System Migration

Oil & Gas, Upstream // Gulf of Mexico


  • The Challenge

The outdated Control System Infrastructure lacked modern performance enhancements and advanced features.

Obsolete Process Control Network appliances and architecture lacked scalability and posed risks to both operations and security.

Unsupported Windows operating systems increased exposure to cyber threats and compliance issues.

A live system upgrade required a structured approach to ensure zero impact on ongoing operations.

  • Our Solution

On-Process Control System Migration (OPM) to the latest Honeywell Experion® PKS software, incorporating critical system components such as enterprise models, trends, control modules, SCADA points, and operator graphics.

PCN Network Redesign to implement Fault-Tolerant Ethernet (FTE) with the latest Cisco network appliances, ensuring enhanced reliability and redundancy.

System Architecture Upgrade, transitioning PCN servers and operator stations from a Microsoft Workgroup to a Domain, improving security and access management.


Comprehensive Factory Acceptance Testing (FAT) of integrated software and hardware to mitigate risks before deployment.

On-Process Field Installation & Commissioning, ensuring a seamless transition to the upgraded system while maintaining operational continuity.

  • The Results

With a comprehensive implementation plan and rigorous testing, the solution was commissioned without operational disruption. This seamless transition enabled the client to operate the upgraded system with enhanced reliability, security, and performance, ensuring long-term operational efficiency.

  • The Champion Advantage
Seamless Integration

Delivery of a turnkey solution integrating Honeywell Experion® PKS, FTE networks, Windows domain migrations, and third-party systems eliminated the need for multiple vendors and delivered a cohesive, cost-effective solution.

Client-Centered Execution and Support

Clear communication, hands-on operator training, and a well-documented transition plan empowered facility operations for long-term success.

Scalable and Future-Ready

Solutions designed with a technical and operational cutover plan ensured a disruption-free migration. The FTE network and Windows domain built a flexible foundation for future growth and cybersecurity enhancements.

Smarter Commissioning, Faster Execution

Continuous engagement with our project team from design through commissioning minimized risks, streamlined troubleshooting, and ensured a seamless installation.

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Securing Legacy OT Systems

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Disaster Recovery

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Cisco Catalyst 2960 End of Life: What It Means for OT Environments

Industrial Data Centers: Digital Foundation to Drive Innovation
🚨 Cisco Catalyst 2960 Switches: End of Life & What It Means for OT Systems

If you’re operating industrial control systems, chances are Cisco Catalyst 2960 switches are buried somewhere in your infrastructure. These reliable workhorses have long supported OT environments—but Cisco has officially announced their End of Life (EOL).

For facilities relying on these switches for SCADA, PLC, or DCS networks, the implications are serious:
🔒 Increased cybersecurity risk
⚠️ Unplanned downtime
💸 Rising replacement costs

❓What Does EOL Mean for Catalyst 2960?

Cisco’s EOL designation means that the Catalyst 2960 switches will:

  • ❌No longer receive software updates or critical security patches 
  • 📞No longer be supported under standard Cisco TAC
  • 🧩Become harder (and pricier) to source due to limited hardware availability

In OT environments, this creates major concerns such as: 

  • 🔐Incompatibility with modern security standards 
  • 🔧Lack of support during failures or cyber incidents 
  • 🛑Disruptive outages caused by aging hardware 
  • 🛑Growing attack surface due to outdated firmware 

⚠️The Risk of Doing Nothing

Sure, the 2960 might still “work”…
But in regulated or mission-critical facilities, relying on unsupported hardware is a liability.
These switches are often deeply integrated—meaning failure could affect production, safety, and compliance.

🛠️Champion’s OT Mitigation Strategy

Our team brings deep domain expertise in ICS networks and zero-disruption migration planning. Our strategy is built for operational continuity:

1️⃣OT Network Discovery

Full network audit to locate 2960s, identify dependencies, and assess criticality.

2️⃣Lifecycle and Risk Analysis

Prioritization using OEM lifecycle data, operational impact, and supportability.

3️⃣Replacement Roadmap

Phased rollout using industrial-grade, Cisco-approved switches ensuring: 

  • Compatibility with your OT protocols 
  • Segmentation and VLAN design 
  • Ruggedization for harsh environments

4️⃣Secure Network Design and Hardening

We go beyond replacement to modernize your OT network:

  • ISA/IEC 62443 alignment
  • Security Zone segmentation
  • VLAN/firewall rules
  • Zero Trust principles

5️⃣Project Execution and Commissioning

Planned and executed by our experienced OT teams during low-risk windows, minimizing downtime and maintaining system integrity.

6️⃣Ongoing Support

Post-upgrade monitoring, health checks, and managed support for sustained reliability.

🏆Why Champion?

With decades of control system integration experience, we’ve successfully delivered secure migrations across:

  • 🛢️ Oil & Gas
  • 🧪 Chemicals
  • ⚡ Utilities
  • 🏭 Manufacturing
  • 🚢 Marine & Terminals

In these environments, downtime isn’t an option—and safety is non-negotiable.

💡Final Thoughts

EOL for the Catalyst 2960 isn’t just a hardware sunset. It’s a strategic opportunity to strengthen your OT network’s security, resilience, and performance.

Let’s modernize your network—on your terms.

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.

 Contact an expert
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Network Segmentation to Enhance OT Cybersecurity

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