Industrial IT and OT Networks
Design, validation and commissioning of industrial networks, plus the industrial-grade hardware they run on, for integrators, EPCs, OEMs and plant owners.
Reference system
Symptoms
When this matters
If any of these describe your environment, this is the conversation to have.
- 01A production line or process stops because a flat office-grade network carried plant traffic.
- 02The control network was built by several contractors, with no single plan for addressing, VLANs or redundancy.
- 03A new line, skid or plant needs a ring that recovers in milliseconds and has been proved before go-live.
- 04Office IT and the plant network touch, but nobody has defined what may cross.
- 05An integrator needs a specialist for the network and hardware side so they can focus on controls.
Scope
What KINNEX delivers
Industrial networks have a different job from office networks: they carry control traffic that must arrive, on time, every time, and recover from a fault faster than a process can notice. We engineer, validate and commission those networks, and supply the industrial hardware they run on.
- Industrial network architecture, IP, VLAN, ACL and QoS planning for SCADA, DCS, PLC, MES and BMS.
- Redundant ring design (PRP, HSR, MRP, ERPS), pilot-ring set-up, failover testing and validation.
- Commissioning support, FAT and SAT readiness, and a complete documentation pack.
- Industrial switches, gateways, servers, workstations, rugged laptops and storage supplied on one order.
- IT and OT segmentation using the Purdue model, with secure vendor remote access.
- Delivered behind your brand, alongside you as a named specialist, or directly with the plant owner.
Capability catalogue
Everything this covers
95 capabilities, scoped, sourced and delivered under one contract. Search for the exact term you use.
95 capabilities
OT network architecture and planning12
A plan for the whole plant, before a single switch is mounted.
- Industrial OT network architecture for SCADA, DCS, PLC, MES, BMS and IIoT
- Purdue-model levels, zones and conduits
- IP addressing plan, subnetting and naming standard
- VLAN design and segmentation by cell, line and function
- Access control lists (ACLs) and traffic-flow definition
- Quality of service (QoS) for control, safety and video traffic
- Multicast design for protocols such as PROFINET and EtherNet/IP
- Redundancy and single-point-of-failure analysis
- Cable-route, panel and cabinet planning
- Brownfield network discovery and migration planning
- Greenfield design for new plants, lines and skids
- Network design for hazardous, outdoor and high-temperature areas
Redundant ring topologies and validation10
Recovery in milliseconds, proved on a test bench or on site before go-live.
- Ring redundancy: PRP, HSR, MRP, ERPS and RSTP
- Dual-homing and ring-coupling designs
- Pilot-ring set-up and bench testing
- Failover-time measurement under load
- Link and switch failure testing with packet-loss measurement
- Latency and jitter measurement for control traffic
- Storm control, loop prevention and broadcast containment
- Time synchronisation: PTP (IEEE 1588) and NTP
- Bandwidth and capacity validation
- Test reports for FAT and SAT
Industrial protocols and integration12
- Modbus TCP and Modbus RTU gateways
- PROFINET and PROFIBUS networks
- EtherNet/IP and CIP
- OPC UA and OPC DA servers and gateways
- IEC 61850 for substations and power automation
- DNP3 and IEC 60870-5-104 for utilities
- BACnet and KNX for building automation
- MQTT and Sparkplug B for IIoT
- Serial-to-Ethernet device servers and protocol converters
- SCADA, historian and MES connectivity
- Remote I/O and PLC network integration
- Vendor-specific protocols and legacy fieldbus bridging
Commissioning, FAT and SAT10
- Factory acceptance test (FAT) network preparation
- Site acceptance test (SAT) network testing
- Staged commissioning and live cut-over in shutdown windows
- Rollback plans and contingency planning
- Switch configuration, staging and burn-in
- Network documentation pack: IP plan, VLAN plan, configurations, test reports
- As-built drawings and panel schedules
- Operator and maintenance training
- Knowledge transfer and post-handover support
- Punch-list and snag management
Industrial hardware supply15
- Industrial managed and unmanaged switches: DIN-rail, rack and rugged
- PoE industrial switches for cameras and access points
- Industrial routers, gateways and wireless access points
- Industrial firewalls and secure remote-access appliances
- Industrial PCs, HMI panels and edge computers
- Servers for SCADA, historian and virtualisation
- Engineering workstations and laptops
- Rugged laptops and tablets for field commissioning
- Handhelds, barcode scanners and RFID readers
- NAS, SAN and storage for plant data
- UPS, DIN-rail power supplies and surge protection
- Industrial enclosures, racks and cooling
- Fibre, copper and industrial-rated cabling and connectors
- SFP transceivers: multimode, single-mode and extended-temperature
- Single PO, GST invoicing and OEM warranty
IT and OT security11
- IT and OT segmentation with industrial firewalls and a DMZ
- IEC 62443-aligned zone and conduit design
- Secure vendor and contractor remote access with session recording
- Jump hosts, bastion access and multi-factor authentication
- Passive asset discovery and network monitoring
- OT anomaly detection and threat monitoring
- Patch and vulnerability management for control systems
- Backup and restore of controllers, HMIs and servers
- Air-gap, removable-media control and USB hygiene
- Whitelisting and endpoint protection suited to industrial hosts
- Security assessment and risk register for the plant network
Wireless and mobility in the plant7
- Industrial Wi-Fi for handhelds, AGVs and vehicle terminals
- Roaming and latency design for moving equipment
- Point-to-point and mesh wireless links
- Private LTE and 5G options through specialists
- RFID and RTLS for asset and personnel tracking
- Wireless survey in metal-rich and dusty environments
- Hazardous-area rated wireless equipment
Industries and applications10
- Process plants: chemical, oil and gas, petrochemical
- Power and energy: generation, substations, renewables and distribution
- Discrete manufacturing: automotive, engineering and assembly
- Water, wastewater and utilities
- Pharmaceuticals and life sciences
- Food and beverage
- Buildings and infrastructure: BMS, tunnels and metro
- Ports, logistics and material handling
- Mining, cement and steel
- Automation OEMs and skid builders
Engagement models8
- Sub-vendor delivery behind your brand, with NDA as standard
- Named as a specialist in your bid or proposal, with joint kick-off
- Direct engagement with the plant owner
- Design-only, supply-only or design-and-supply scopes
- Fixed-fee proposals after a short scoping call
- Clear commercial terms: scope, validity, milestones, GST, IP and confidentiality
- Top-tier specialist engineers brought in for complex phases
- Maintenance and support under an agreed SOP and SLA
Nothing listed under that term yet. If you need it, ask: we can usually source or deliver it through a specialist team. Tell us what you need.
The site, in 3D
A plant network that recovers before the process notices
Redundant rings proved on the bench and on site, with a defined boundary between plant and office IT.
- Redundant ring
- Cells and PLCs
- IT and OT boundary
- FAT and SAT
Real-time 3D illustration of a typical site, not a specific client project.
Use cases
Where this shows up
Typical situations that lead an organisation to this work.
01
An automation integrator needing the network design and industrial switches for a new line.
02
A plant replacing a flat network with segmented, redundant rings during a shutdown window.
03
A utility or process plant separating business IT from the control network.
Delivery method
How the work runs
Architecture before equipment. Validation before handover.
Stage 01 of 6
Assess
Review the process, the control system, existing network, availability needs and safety constraints.
Stage 02 of 6
Design
Produce the architecture, IP and VLAN plans, ring topology, security zones and hardware specification.
Stage 03 of 6
Implement
Stage and configure switches, build a pilot ring, install and cut over in agreed windows.
Stage 04 of 6
Validate
Prove failover times, loss, latency and protocol behaviour; support FAT and SAT.
Stage 05 of 6
Document
Hand over IP plan, VLAN plan, configurations, test reports and as-built drawings.
Stage 06 of 6
Support
Knowledge transfer and post-handover support, with maintenance under an agreed SOP and SLA.
Free tool
Subnet calculator and VLAN plan
Work out subnets, then lay plant zones into one address block with room to grow. A starting point for the design conversation.
Subnet calculator
- Network
- 192.168.10.64/26
- Subnet mask
- 255.255.255.192
- Wildcard
- 0.0.0.63
- Broadcast
- 192.168.10.127
- First usable
- 192.168.10.65
- Last usable
- 192.168.10.126
- Usable hosts
- 62
- Total addresses
- 64
VLAN and IP plan
Set the address block for the site and how many devices each zone needs. The planner adds headroom and fits the zones into the block, largest first, with no overlaps.
| Zone | VLAN | Devices | Subnet | Gateway | Usable |
|---|---|---|---|---|---|
| Does not fit | |||||
| 10.20.3.128/25 | 10.20.3.129 | 126 | |||
| 10.20.2.0/24 | 10.20.2.1 | 254 | |||
| 10.20.0.0/23 | 10.20.0.1 | 510 | |||
| 10.20.3.0/25 | 10.20.3.1 | 126 | |||
| Does not fit | |||||
| Does not fit | |||||
| Does not fit |
The block is too small for: Wireless and handhelds, Level 3 operations and servers, Network management, DMZ and remote access. Use a shorter prefix.
A starting layout only. Real plant plans also reflect firewall zones, redundancy, vendor address rules and existing equipment.
How we take this on
One contract. The right specialist for every part
Your project is wider than any single team. We scope all of it, source all of it and carry the responsibility for all of it.
- 01
Scope
We survey, size and specify against standards and your operating reality, not against a brochure.
- 02
Source
Any make, any model, from the manufacturer, distribution or registered importers. GST-compliant invoicing, warranty and returns handled for you.
- 03
Deliver
KINNEX engineers do the work we do every day. Where a job needs a specialist, we bring in the right expert team as a sub-order under your single contract.
- 04
Own
One scope, one SOP, one SLA and one point of accountability, whoever is on site.
Standards and terms
Standards we design to, and the terms you will hear
Specifications are written against recognised standards. Here is the vocabulary, in plain language.
- IEC 62443 (industrial automation and control security)
- ISA/IEC 62443 zones and conduits
- Purdue Enterprise Reference Architecture
- IEC 62439 (PRP and HSR redundancy)
- IEC 62439-2 (MRP) and ITU-T G.8032 (ERPS)
- IEEE 802.1D and 802.1w (spanning tree)
- IEEE 1588 (precision time protocol)
- IEC 61850 (power utility automation)
- IEC 61158 and IEC 61784 (fieldbus and real-time Ethernet)
- OPC UA (IEC 62541)
- NAMUR and ATEX / IECEx for hazardous areas
- IP and NEMA enclosure ratings
- EN 50155 and EN 50121 for rail and EMC where relevant
- ISO/IEC 27001 aligned practices
- OT vs IT
- Operational technology runs physical processes and must be available and predictable. Information technology runs business data and favours flexibility. The two need a defined boundary.
- SCADA, DCS, PLC
- Supervisory control and data acquisition, distributed control systems and programmable logic controllers: the systems that run a plant.
- Purdue model
- A layered reference architecture that separates field devices, control, supervision and business IT.
- Ring redundancy
- Switches joined in a loop so traffic still gets through if one link or switch fails.
- PRP and HSR
- Redundancy protocols that send each frame twice over two paths, giving zero recovery time.
- MRP and ERPS
- Ring protocols that recover from a break in milliseconds, widely used in industrial networks.
- RSTP
- Rapid spanning tree: a general loop-prevention protocol that recovers more slowly than ring protocols.
- FAT and SAT
- Factory acceptance test and site acceptance test: the formal tests proving a system works before and after installation.
- DMZ
- A buffer network between IT and OT where data is exchanged under strict rules.
- Zones and conduits
- IEC 62443 terms: groups of assets with equal security needs, and the controlled paths between them.
- OPC UA
- A secure, platform-independent standard for exchanging data between industrial devices and software.
- PTP
- Precision time protocol: sub-microsecond clock synchronisation for motion control and power systems.
- DIN rail
- The standard metal rail inside control panels on which industrial switches and power supplies are mounted.
- ATEX / IECEx
- Markings for equipment safe to use in explosive atmospheres.
- SOP and SLA
- The documented procedures for maintaining the network, and the response targets agreed for it.
Brands
Any make. Sourced, supplied and supported
We specify against your requirement and standards, then source the right product from the manufacturer, distribution or registered importers. Delivered, installed and supported under one contract.
Industrial automation and OT networking
Industrial Ethernet, automation platforms, SCADA and OT security.
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GE Vernova
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Fuji Electric
Hitachi
Danfoss
Festo
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HMS Networks- Moxa
- Hirschmann
- Westermo
- ORing
- Emerson
- Ruijie Networks
- Red Lion
- Lantronix
- Weidmuller
- Claroty
- Nozomi Networks
- Dragos
- Waterfall Security
- AVEVA
- Kepware
- Delta Electronics
- Eaton
- Endress+Hauser
- SMC
- Turck
- Banner Engineering
- SICK
- Keyence
- Eurotech
- Digi International
- ProSoft
- Kyland
- Planet Technology
- Korenix
Networking, Wi-Fi and SD-WAN
Switching, routing, wireless, SD-WAN and application delivery.
- Cisco
Aruba
Juniper Networks
Ubiquiti
TP-Link
D-Link
Netgear
Cambium Networks- Fortinet
Huawei
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Arista Networks
Dell Technologies
Zyxel- Cisco Meraki
Alcatel-Lucent Enterprise
Allied Telesis
Array Networks
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F5
Citrix
Radware
HPE
VMware
Palo Alto Networks
Tejas Networks
Nokia
Ericsson- Ruckus Networks
- Extreme Networks
- Ruijie Networks
- Juniper Mist
- Digisol
- A10 Networks
- Versa Networks
- Peplink
- Cradlepoint
- Teltonika
Rugged, mobile and field computing
Rugged laptops, tablets, handhelds, scanners and label printers.
Panasonic Toughbook
Dell Rugged
Zebra Technologies- Honeywell
Samsung Galaxy Tab Active
Datalogic
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Unitech
Sunmi
Motorola Solutions
Kyocera DuraForce
Brady
Epson
Citizen
Bixolon- Getac
- Bluebird
- Newland
Show 11 more brands
- Cipherlab
- Pidion
- Xplore
- Durabook
- Juniper Systems
- Sonim
- CAT Phones
- TSC
- Godex
- SATO
- Intermec
Servers, storage and data-centre compute
Rack, tower and edge servers, SAN, NAS, all-flash and tape.
- Dell Technologies
- HPE
Lenovo- Cisco UCS
Supermicro
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IBM- Huawei
Inspur
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Pure Storage
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ASUS
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Marvell
Broadcom
Arm
SK hynix
Kioxia
SanDisk
Transcend- Quantum
- Asustor
- Kingston
- Crucial
- Nimble Storage
- Mellanox
- Ampere
Power, cooling, racks and data-centre facility
UPS, batteries, PDUs, precision cooling, racks and monitoring.
APC- Schneider Electric
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Rittal
Exide
Cummins
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Liebert- ABB
- Siemens
- Hitachi Hi-Rel
Havells
Tripp Lite
Kohler
Caterpillar
Perkins- Eaton
Show 24 more brands
- Delta Electronics
- Legrand
- Netrack
- Valrack
- Raritan
- Socomec
- Riello
- Numeric
- Luminous
- Microtek
- Amara Raja
- Mahindra Powerol
- Panduit
- Emerson
- Su-Kam
- Livguard
- Okaya
- CyberPower
- Centiel
- Piller
- Ashok Leyland
- Server Technology
- Sensaphone
- AKCP
Product names, logos and brands are property of their respective owners and are used for identification only. Don't see what you need? We can usually source it, including through registered importers.Ask us.
Technology fit
The technology categories this work draws on.
- Industrial Ethernet switches, DIN-rail and rugged
- Ring redundancy: PRP, HSR, MRP, ERPS, RSTP
- Industrial protocols: Modbus TCP, PROFINET, EtherNet/IP, OPC UA, IEC 61850, DNP3
- IEC 62443-aligned zones and conduits
- Rugged laptops, industrial PCs and HMI
- Remote access with session recording
Environments
Where this applies
Reading
Related insights
Industrial IT and OT Networks
Secure remote access for plant vendors and OEMs
Vendors need to reach controllers for support. How jump hosts, time-limited access and session recording keep it safe.
Industrial IT and OT Networks
IEC 62443 and the Purdue model for plant managers
Zones, conduits and levels without the jargon. How industrial security standards shape practical network design.
Industrial IT and OT Networks
Redundant rings explained: RSTP, MRP, ERPS, PRP and HSR
Different industrial redundancy protocols recover in different times. A plain comparison and where each is used.
Industrial IT and OT Networks
Seven network mistakes that stop production lines
Flat networks, unmanaged switches and untested redundancy are common in plants. How to find and fix them before the next shutdown.
Questions
Frequently asked questions
We build the ring on the bench or on site, then deliberately break links and power down switches while measuring how long traffic takes to recover and whether any control traffic is lost. The results go into a test report, so the redundancy is proved, not assumed.
We design to your platform and specify whatever the project standardises on, including Moxa, Hirschmann, Westermo, ORing, Phoenix Contact, Cisco, Ruijie and Advantech, and source from the manufacturer or distribution.
Yes. Many integrators bring us in as a sub-vendor under their brand, with an NDA as standard. We can also be named in a bid, or work directly with the plant owner.
Using the Purdue model and IEC 62443-aligned zones and conduits: industrial firewalls and a DMZ at the boundary, strictly defined flows, and vendor remote access that goes through a controlled, recorded jump host.
We prepare the network side for factory and site acceptance tests, run the network tests, and supply the reports. Controls testing stays with the control-system integrator.
Yes. Industrial switches, servers, engineering workstations, rugged field laptops for commissioning, storage and power can all be supplied on one purchase order.
Discuss an industrial network
Tell us the site, the constraint or the outcome you need, and we will come back with the right next step.