Process Safely. Protect Continuously.
SECURING CHEMICAL MANUFACTURING
We help chemical manufacturers protect process control systems, safeguard hazardous operations, and maintain safety integrity through comprehensive OT security aligned with CFATS, PSM, and RMP requirements.
"Chemical manufacturing involves inherently hazardous processes where cyber incidents can trigger chemical releases, explosions, or toxic exposures - making cybersecurity fundamental to process safety and community protection."
Chemical Industry Cyber Security Challenges
Process Safety, Worker Protection and Environmental Stewardship are critical imperatives for chemical operations.
Chemical manufacturing depends on sophisticated process control systems including distributed control systems (DCS) managing reactions, separations, and material transfers; safety instrumented systems (SIS) preventing catastrophic events; emergency shutdown systems (ESD) responding to abnormal conditions; and advanced process control (APC) optimizing complex chemical processes. These systems handle hazardous materials at extreme temperatures and pressures requiring precise control.
The sector faces unique cybersecurity challenges: CFATS (Chemical Facility Anti-Terrorism Standards) requirements for high-risk facilities, process safety management (PSM) obligations under OSHA, Risk Management Plan (RMP) requirements under EPA, inherently hazardous processes where control system failures can cause catastrophic releases, and legacy DCS platforms with limited security capabilities operating in critical safety roles.
With demonstrated cyber attacks on chemical facilities, increasing regulatory scrutiny of cybersecurity for high-consequence facilities, and the potential for cyber incidents to cause major chemical accidents affecting surrounding communities, chemical manufacturers must implement OT security programs that integrate with process safety management to prevent catastrophic events.
Chemical Industry Threat Environment
High-Consequence Threats
- Process control manipulation causing runaway reactions or hazardous chemical releases
- Safety instrumented system (SIS) compromise disabling critical safety barriers
- Emergency shutdown system attacks preventing response to abnormal conditions
- Ransomware forcing unsafe plant shutdowns or preventing emergency response
- Hazardous material management system breaches affecting inventory or handling
- Environmental monitoring system manipulation concealing emissions or releases
Catastrophic Consequences
- Chemical releases causing worker casualties, community evacuations, or environmental disasters
- Explosions or fires from loss of process control causing fatalities and facility destruction
- CFATS violations resulting in facility shutdowns and DHS enforcement actions
- PSM/RMP violations triggering OSHA citations and EPA enforcement
- Multi-million dollar environmental cleanup and liability from uncontrolled releases
- Permanent facility closure from catastrophic events destroying public trust
Chemical Manufacturing Systems We Secure
Process Control
Distributed control systems (DCS), programmable logic controllers (PLCs), and advanced process control (APC) managing chemical reactions and separations.
Safety Systems
Safety instrumented systems (SIS), emergency shutdown systems (ESD), burner management, and safety integrity level (SIL) rated safety functions.
Batch Operations
Batch control systems, recipe management, sequential function charts (SFC), and electronic batch records for specialty chemicals.
Asset Monitoring
Rotating equipment monitoring, leak detection systems, corrosion monitoring, and predictive maintenance platforms.
Environmental Controls
Emissions monitoring, wastewater treatment controls, air quality systems, and environmental compliance reporting.
Material Management
Inventory management, hazardous material tracking, tank farm monitoring, and loading/unloading automation for chemicals.
Chemical Process Safety & Security Strategy
Integrated Process Safety Approach
For chemical manufacturers, OTFIELD provides OT cybersecurity programs integrated with process safety management - recognizing that cybersecurity is a critical layer of protection preventing major chemical accidents and protecting surrounding communities.
We understand chemical operational realities: processes involve inherently hazardous materials, safety systems cannot be compromised under any circumstances, DHS CFATS compliance is mandatory for high-risk facilities, process safety management (PSM) and Risk Management Plans (RMP) require cybersecurity considerations, and legacy DCS platforms require specialized security approaches. Our programs deliver security that enhances rather than conflicts with process safety.
Process Safety-Integrated Security Implementation
Phase 1: Process Hazard & Cyber Risk Assessment
Objective: Identify cyber risks to process safety and high-consequence scenarios
- Assess safety-critical control systems and safety instrumented systems (SIS)
- Evaluate cyber attack scenarios against process hazard analysis (PHA) findings
- Identify cyber threats to safety barriers and layers of protection
- Review emergency shutdown systems and alarm management
- Assess CFATS risk-based performance standards (RBPS) compliance
- Consider cyber scenarios in risk management plan (RMP) worst-case scenarios
This assessment integrates cybersecurity with process safety management to prevent major chemical accidents.
Phase 2: Chemical Security & Compliance Program
Objective: Implement controls protecting process safety while meeting CFATS requirements
Regulatory Framework:
- CFATS (Chemical Facility Anti-Terrorism Standards) - DHS cybersecurity requirements
- OSHA PSM (Process Safety Management) - Cybersecurity in PSM programs
- EPA RMP (Risk Management Plan) - Cyber considerations in prevention programs
- IEC 61511 - Functional safety and SIS cybersecurity
- IEC 62443 - Industrial control systems security for chemical processes
Chemical-Specific Controls:
- Safety instrumented system (SIS) protection maintaining SIL ratings and independence
- Process control system security preventing unauthorized setpoint changes
- Emergency shutdown system integrity ensuring fail-safe operation
- Network segmentation isolating safety-critical systems from business networks
- Hazardous material management system security
- Environmental monitoring and compliance system protection
- Incident response procedures integrated with emergency response plans
- Management of change (MOC) incorporating cybersecurity considerations
- CFATS security vulnerability assessment (SVA) and site security plan updates
CFATS Cybersecurity Compliance
We support high-risk chemical facilities in meeting CFATS cybersecurity requirements:
RBPS #8 - Cybersecurity
- Security vulnerability assessment including cyber risks
- Site security plan with cybersecurity measures
- Access controls for control systems and networks
- Monitoring and detection of unauthorized access
- Incident response and recovery procedures
DHS Inspection Support
- SVA documentation and updates
- Site security plan maintenance
- Authorization inspection preparation
- Compliance inspection response
- Corrective action plan development
Chemical Manufacturing Success Factors
Chemical manufacturers must address these critical considerations:
- Can we secure process control without compromising safety system independence?
- How do we protect SIS while maintaining SIL ratings and fail-safe operation?
- Are we meeting CFATS cybersecurity requirements for high-risk facilities?
- Can we integrate cybersecurity into PSM and RMP programs?
- How do we prevent cyber attacks from causing major chemical accidents?
- Do we have incident response integrated with emergency response plans?
Success requires integrating cybersecurity with process safety management to prevent catastrophic chemical events.
Regulatory & Standards Landscape
- CFATS - Chemical Facility Anti-Terrorism Standards cybersecurity requirements (DHS)
- OSHA PSM - Process Safety Management including cybersecurity considerations
- EPA RMP - Risk Management Plan prevention program requirements
- IEC 61511 - Functional safety - Safety instrumented systems for process industry
- IEC 62443 - Industrial automation and control systems security
Prevent Catastrophic Events. Protect Communities.
Chemical manufacturers cannot risk cyber incidents that trigger chemical releases, explosions, or toxic exposures. Discover how we integrate cybersecurity with process safety management to prevent major chemical accidents.
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