Setting up an IEC 62443-aligned ICS security test bed

Thanks to unsolicited attention from state-backed threat actors and hacktivists, in the world of critical infrastructure, the stakes are incredibly high. A cyberattack on an Industrial Control System (ICS) could lead to catastrophic consequences, from widespread power outages, critical system shutdowns and even environmental disasters. With ongoing active conflicts and cold skirmishes across the globe, cyberspace is becoming a conflict zone to settle geopolitical scores and critical infrastructure becomes a target to go after.

All major conflicts of the last decade have had a cyber dimension to it and with cyberattacks becoming more complex, persistent and unpredictable, critical infrastructure is now facing risks it has never been exposed to before.    

To mitigate such risks, a robust, phased and proactive approach to industrial cybersecurity is essential. One of the most effective ways to achieve this is through the establishment of a dedicated ICS security test bed, meticulously designed to test assets for their alignment with international standards such IEC 62443-4-1 and IEC 62443-4-2.

For establishments connected with the defense of the country, a test bed is a security imperitive.

Today’s blog post will guide you through the significance, benefits, and key considerations for setting up such a test bed, ensuring your critical infrastructure remains resilient against evolving cyber threats.

Don’t forget to check out our previous blog post on the German NIS 2 Implementation Act here.

Why should you go for an ICS security test bed?

At its core, a security test bed is a controlled, isolated environment that replicates a live ICS network and its components. It serves as a vital testing ground for:

• Vulnerability assessment: Safely identifying and understanding weaknesses in ICS hardware, software, and network configurations without risking any form of operational disruption (as the environment is a controlled one).

• Corelating security and performance: Assets and systems can be tested to see if security measures can impact performance or vice-versa

• SAT: Security Acceptance Testing can also be done through a test bed 

• Security control validation: Testing the effectiveness of security measures (firewalls, intrusion detection systems, diodes, SIEMs, SOARs, access controls) before deployment in a production environment.

• Incident Response training: Simulating various cyberattack scenarios to train personnel on detection, containment, eradication, and recovery procedures.

• Secure system design and development: Prototyping and testing new ICS components and systems with security built-in from the ground up.

• Forensic analysis: Investigating the root causes of simulated attacks and understanding attack methodologies.

• Research and Development: Exploring new security technologies and defense strategies tailored for ICS environments.

An active test bed may even be used to test critical devices and systems (that go into critical infrastructure) for an extended period of time.

Aligning with IEC 62443-4-1 (Secure Product Development Lifecycle Requirements)

IEC 62443-4-1 focuses on the secure development lifecycle of ICS components and systems. When building your test bed, consider how it can support these requirements:

• Security by design: Use the test bed to evaluate products and systems from the initial design phase, ensuring security requirements are integrated early.

• Secure development environment: The test bed can host secure development environments where developers can work on ICS software and firmware, with security tools and practices in place.

• Compliance testing: Systems can also be tested to check for compliance with national and global security mandates

• Requirements definition: Use the test bed to validate security requirements against actual system behavior.

• Secure coding guidelines and testing: Implement and enforce secure coding practices within the test bed, and use it to perform various forms of security testing (e.g., static and dynamic analysis, penetration testing) on developed code.

• Vulnerability management: Develop and test vulnerability management processes, including patch management and configuration management, within the test bed.

• Documentation and guidance: The test bed can be used to generate and validate security documentation and operational guidance for the secure use of ICS components.

• Validate in-built security measures: In cases where the OEM claims of in-built security measures, the same can be tested here.

• Check for supply chain poisoning

Aligning with IEC 62443-4-2 (Technical Security Requirements for IACS Components)

IEC 62443-4-2 details the technical security requirements for Industrial Automation and Control Systems (IACS) components. Your test bed should enable you to assess and validate these aspects:

• Identification and Authentication Control (IAC): Test various authentication mechanisms (such as for instance multi-factor authentication, strong passwords) and user role management within the simulated environment.

• Use Control (UC): Validate access control policies, ensuring that users and processes only have the necessary permissions.

• System Integrity (SI): Test mechanisms to ensure the integrity of software, firmware, and data, such as secure boot and digital signatures.

• Data Confidentiality (DC): Evaluate encryption protocols and secure communication channels to protect sensitive data in transit and at rest.

• Restricted Data Flow (RDF): Test firewall rules, network segmentation, and demilitarized zones (DMZs) to control communication between different security zones.

• Timely Response to Events (TRE): Assess the test bed's ability to detect security events, generate alerts, and enable timely responses from security personnel.

• Resource Availability (RA): Test the resilience of the ICS to denial-of-service attacks and other threats that could impact availability.

• Session Management (SM): Validate secure session management practices for human-machine interfaces (HMIs) and other access points.

• Security Hardening (SH): Test configuration hardening guidelines and their effectiveness in securing ICS components.

Key considerations for setting up your test bed

• Isolation: The test bed must be completely isolated from your production network to prevent any accidental impact on live operations. This means physical and logical separation.

• Realistic Representation: Strive for a realistic representation of your production ICS environment. This includes:

  • Hardware: Use similar PLCs, RTUs, HMIs, and other control devices.

  • Software: Install the same operating systems, control applications, and firmware versions.

  • Network topology: Replicate the network architecture, including firewalls, switches, and routing.

  • Data: Utilize representative process data, ideally sanitized versions of real-world data.

• Scalability: Design the test bed to be scalable, allowing you to add more components and scenarios as your needs evolve.

• Automation: Automate test case execution, data collection, and reporting wherever possible to increase efficiency and consistency.

• Tools and Software: Invest in appropriate security tools, including:

  • Vulnerability scanners

  • Penetration testing tools

  • Intrusion detection/prevention systems (IDS/IPS)

  • Security Information and Event Management (SIEM) solutions

  • Network traffic analyzers

  • Forensic analysis tools

• Staffing and Expertise: Ensure you have personnel with expertise in both ICS operations and cybersecurity to effectively manage and utilize the test bed.

• Documentation: Thoroughly document the test bed's architecture, configurations, test procedures, and results.

• Lifecycle Management: Treat the test bed as a living system. Regularly update its components, software, and test cases to reflect changes in your production environment and the threat landscape.

Benefits of an IEC 62443-aligned test bed

• Enhanced security posture: Proactively identify and address vulnerabilities before they can be exploited in live systems.

• Reduced risk of operational disruptions: Test security changes and updates in a safe environment, minimizing the chance of downtime.

• Improved compliance: Demonstrate adherence to international security standards like IEC 62443, which is increasingly vital for regulatory and contractual obligations.

• Faster incident response: Train and refine incident response plans, leading to quicker and more effective recovery from cyberattacks.

• Cost savings: Prevent costly breaches and associated fines, downtime, and reputational damage.

• Increased confidence: Build confidence in the security of your ICS, both internally and among stakeholders.

• Innovation: Foster a culture of continuous security improvement and innovation in ICS security.

Building an IEC 62443-aligned ICS security test bed is a critical investment in the resilience and continuity of your operations. By providing a safe, controlled and realistic environment for rigorous security testing and training, you empower your organization to stay ahead of evolving threats and safeguard the vital services delivered by critical infrastructure.

Talk to us to learn about how you can establish a multi-tech ICS security test bed, talk to us.