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Hindalco India - Protecting plant's productivity with Integration of IT/OT infrastructure

Ensuring security and reliability in OT systems across the plant

Hindalco India - Protecting plant's productivity with Integration of IT/OT infrastructure

Ensuring security and reliability in OT systems across the plant

Metals

Hindalco Industries Limited

Mumbai India

Hindalco Industries Limited, FRP, Hirakud

Sambalpur,

India

Siemens Xcelerator

Award Winner

The customer’s major objective was integration of IT and OT systems for improving security posture and driving innovation through secure data exchange. The heterogeneity in technology, communication protocols, systems pertaining to various generation and mix of OEMs added to the overall complexity of the environment, which made it difficult to create a uniform security concept. In addition, many industrial control systems were developed before safety was even an issue, which meant that older systems were running on operating systems that lacked essential safety functions.
The needs were mentioned as:

Developing a flexible, scalable, and reliable OT backbone in line with IEC62443.
Handle data traffic effectively between IT and OT.
Real-time monitoring of the network and cyber incidents.
Implementing a secure remote access solution.
Support the digitalization initiatives.

Siemens collaborated with Hindalco to jointly develop a comprehensive plan for identifying solutions that encompass a holistic security concept. The implementation roadmap was designed, discussed, and agreed upon collaboratively. Consequently, Hindalco selected Siemens as their preferred partner for the implementation after multiple rounds of discussions. Network Security Services - Industrial Generation Firewall (NGFW) and IDMZ

Secure Reference Architecture: Plant areas were divided into multiple security zones, with conduits defined based on the IEC 62443 standard. Segmentation was implemented to separate IT, OT, and DMZ using next-generation firewalls. The OFC backbone infrastructure was established by laying over 15 kilometers of cable across the plant, connecting 22 locations.
IT-OT Integration and DMZ Formation: The enterprise network and OT were segregated using redundant Palo Alto firewalls. A demilitarized zone (DMZ) was configured to restrict traffic between IT and OT. Communication was established between enterprise systems like Oracle, SIEM, and remote access server with DMZ servers, as well as between DMZ servers and OT systems.
Secure Remote Access: A Sinema Remote Connect server was installed along with scalance security appliances. A jump server was configured in the DMZ to facilitate secure remote access.
Log Collection and NTP : Sinec INS sofware was installed to collect syslogs from Windows machines and network devices, transferring these logs to the customer’s SIEM. GPS clock hardware was installed, synchronizing all OT Windows systems and network devices over NTP.
Continuous Threat Detection (CTD): A CTD server was installed at the core switch to scan traffic between IT and OT, identifying assets, threats and vulnerabilities.
Network Monitoring: A Sinec NMS server was configured with SNMPv3 protocols to scan all network devices, also configued area-wise network topology for the troubleshooting.

“The project was completed on time and exceeded our expectations. The integration of IT and OT systems has greatly improved our operational processes and security posture.”

Mr. Rahul Kene and Mr. Manish Negi, Hindalco Industries Limited

Enhanced detection and response capabilities allow for quicker identification of security incidents. Furthermore, secured IT-OT integration leverages the benefits of IT technologies being integrated into OT environments, enhancing operational efficiency. OT cybersecurity measures have helped Hindalco not only meet industry standards such as IEC 62443 but also be a front runner in the entire fraternity. A secure, efficient, and resilient operational environment ultimately supports the company's goals and enables long-term success. Overall, with these solutions, the Hindalco team not only addressed risks associated with network segmentation but also added visibility on network infrastructure, threat identification and management, network monitoring and remote access and leveraged benefits of IT-OT integration. This site will serve as a reference for horizontal deployment across other Hindalco plants.

Hindalco is one of India's biggest aluminium manufacturing company and the world's largest flat-rolled products player and recycler of aluminium.

Awards

Best Digitalization Use Case Network and OT-Security CS 2023

Best Digitalization Use Case Network and OT-Security CS

Completion 2024

Hindalco Industries Limited, India - Real-time transparency due to Security Assessments

Sustainability

Release Year 2022

Pulp and Paper Customer -Senseye Predictive Maintenance to monitor machine performance

Completion 2022

EJ Picardie steel plant, France - New security measures due to Security Assessments

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