OT/ICS VAPT

OT/ICS Vulnerability Assessment and Penetration Testing (VAPT)

Find Vulnerabilities in Your Industrial Control Systems Without Putting Operations at Risk

OT/ICS vulnerability assessment and penetration testing (VAPT) identifies and validates security weaknesses in industrial control systems, including PLCs, RTUs, IEDs, HMIs, SCADA servers and industrial networks. It uses controlled, OT-safe techniques that protect availability and safety.

Forti Vision provides OT/ICS VAPT services for power utilities, oil and gas, water, manufacturing and critical infrastructure operators. Our testing is led by engineers with 18+ years of hands-on experience in substation automation, SCADA and industrial networks, and who hold GICSP and ISA/IEC 62443 certifications.

We plan every test around your technology, architecture, protocols, and operational constraints before any testing begins.

Discuss Your OT/ICS VAPT Requirements

Why OT Penetration Testing Is Different from IT Penetration Testing

Conventional IT penetration testing tools and techniques can disrupt industrial control systems. Aggressive scans can freeze or reboot legacy PLCs and IEDs. Exploitation attempts can interrupt control functions.

OT environments often include:

Legacy operating systems that cannot be patched quickly
PLCs, RTUs, IEDs and HMIs with limited processing capacity
Industrial protocols with little or no built-in security
Safety-critical processes that must stay online

A vulnerability rated “low” by an IT scanner can have serious operational consequences in a substation or process plant. Forti Vision combines cybersecurity testing with industrial automation engineering knowledge, so findings are tested safely and interpreted in the context of your operation.

Our OT/ICS VAPT Services

OT Vulnerability Assessment

We identify known vulnerabilities and security weaknesses across in-scope OT systems and supporting infrastructure:

Asset and service identification
Vulnerability identification and validation
Configuration and patch status review
Network exposure analysis
Authentication and security control review
Risk-based vulnerability prioritization

OT Network Penetration Testing

We test the security of your OT network architecture and communication paths:

Network segmentation and zone/conduit enforcement
Firewall rules and OT DMZ controls
Remote access and engineering access paths
Inter-zone communications
Unnecessary network and industrial protocol exposure

PLC, RTU and IED Security Testing

Where technically and operationally appropriate, we assess industrial devices including:

PLCs and controllers
RTUs
IEDs and bay control units (BCUs)
HMIs
Industrial gateways

Device testing is planned around each device’s capabilities and vendor guidance, typically in test environments or approved maintenance windows.

SCADA and HMI Security Testing

We assess SCADA and HMI systems for weaknesses in:

Authentication and user privileges
Application configuration and services
Network exposure and remote access
Communication paths
Underlying operating systems

Industrial Protocol Security Assessment

We examine how industrial protocols are exposed and protected, including:

Modbus TCP/RTU
DNP3
IEC 61850 (MMS, GOOSE, Sampled Values)
IEC 60870-5-104
OPC DA / OPC UA
MQTT
SNMP

The goal is to identify insecure communication paths and confirm that appropriate controls are in place.

Assessment Before Exploitation: How We Keep Testing Safe

A critical part of OT VAPT is deciding what should and should not be actively tested. Before testing, we evaluate:

System criticality and safety requirements
Operational impact and device sensitivity
Approved testing windows
Backup availability and recovery procedures
Vendor recommendations
Approved test methods

Where active exploitation presents unacceptable risk, we use alternative validation techniques. These include configuration analysis, testing on spare or lab equipment, and passive traffic analysis.

Our 7-Step OT VAPT Methodology

Scope and rules of engagement: Define systems, networks, testing windows, permitted techniques and operational restrictions.
OT architecture review: Understand the architecture and identify critical systems and communication paths.
Asset and service identification: Establish in-scope assets and exposed services using OT-safe methods.
Vulnerability assessment: Identify and validate applicable vulnerabilities and weaknesses.
Controlled security testing: Perform authorized, controlled testing where technically appropriate.
Risk analysis: Rate findings by their real impact on your industrial operation, not just generic CVSS scores.
Reporting and remediation: Deliver evidence-based findings and practical remediation guidance.

OT VAPT Report Deliverables

Your report can include:

Executive summary for management
Scope, rules of engagement and methodology
Asset summary
Vulnerability findings with evidence
Risk classification and potential operational impact
Affected systems
Remediation recommendations
Prioritized remediation roadmap
Technical appendix for engineering teams

Standards and Frameworks

Forti Vision aligns OT VAPT activities with recognized industrial cybersecurity standards:

Standard / Framework	How It Applies
IEC 62443	Security requirements for industrial systems and components (62443-3-3, 4-2)
NIST SP 800-82	US guidance on securing and testing industrial control systems
NERC CIP	Vulnerability assessment requirements for bulk electric system operators (CIP-010)
UAE Information Assurance Regulation / DESC standards	UAE federal and Dubai critical infrastructure requirements

Who Needs OT/ICS Penetration Testing?

Power utilities and substations
Oil and gas facilities and pipelines
Petrochemical plants
Water and wastewater utilities
Manufacturing plants
Ports and critical infrastructure
Data centers with BMS, EPMS and industrial control systems
OEMs and system integrators validating products or systems before delivery

Frequently Asked Questions

What is OT/ICS penetration testing?

OT/ICS penetration testing is a controlled security test of industrial control systems that identifies and validates vulnerabilities an attacker could exploit. Unlike IT testing, it is planned around operational safety, using OT-safe techniques and approved testing windows to avoid disrupting production.

Is penetration testing safe for PLCs and SCADA systems?

It can be, when properly planned. Forti Vision defines strict rules of engagement, avoids aggressive scanning on live devices, and tests sensitive equipment in lab or maintenance windows. Where active testing is too risky, we use alternative validation methods.

What is the difference between an OT vulnerability assessment and an OT penetration test?

A vulnerability assessment identifies and prioritizes known weaknesses. A penetration test goes further by attempting to validate whether those weaknesses can actually be exploited, within agreed safety limits.

How often should OT penetration testing be performed?

Most organizations test OT systems annually and after significant changes, such as new network connections, system upgrades or remote access changes. Regulations such as NERC CIP set specific vulnerability assessment intervals for covered assets.

Can you test IEC 61850 substations?

Yes. Forti Vision has deep experience with IEC 61850 substation automation systems, including IEDs, bay controllers, station HMIs and GOOSE/MMS communications. We test them safely using methods suited to protection and control environments.

Do you provide OT VAPT services in the USA and UAE?

Yes. Forti Vision provides OT/ICS vulnerability assessment and penetration testing across the United States and the United Arab Emirates, combining remote analysis with on-site testing where required.

Protect Your Industrial Environment While Testing Its Security

Effective OT VAPT answers two questions:

What vulnerabilities exist?

What do those vulnerabilities mean for your operation?

Forti Vision combines OT engineering knowledge with cybersecurity testing to answer both.

sales@fortivisionllc.com