Outdated Virtual Environments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.
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
8 Months
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.
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.