Industrial Technology & Safety Consultancy

Engineering
Confidence.
Delivering
Certainty.

We integrate cybersecurity, functional safety, digital transformation, and resilience engineering to protect and advance the world's most critical industrial operations.

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IT & OT Cybersecurity Functional Safety Resilience Engineering Industry 4.0 & 5.0 Alarm Management SCADA & Design Engineering Systems Engineering & Assurance
7
Core Capability Domains
IEC
61511 · 62443 Practice
I4/I5
Industry Transformation
OT
Cyber & Safety Integrated

Seven Domains.
One Integrated Approach.

OTONUS delivers across the full spectrum of industrial technology and safety disciplines — each capability reinforced by the others, all executed with engineering rigour.

01

IT & OT Cybersecurity

End-to-end cybersecurity programs across IT and OT environments — IEC 62443, NIST CSF, and ACSC Essential Eight aligned to your operational risk profile.

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02

Functional Safety

Full SIS lifecycle assurance — HAZOP, LOPA, SIL determination, SRS design, SIL verification, FSA, and competency frameworks to IEC 61511.

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03

Resilience Engineering

Barrier-based thinking, compound failure modelling, weak-signal detection, and leading indicators that reduce latent failure exposure and sustain throughput.

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04

Industry 4.0 & 5.0 Strategy

IIoT, digital twins, edge–cloud architecture, and human-centred decision support — transforming data into operational intelligence with safety and cyber controls embedded.

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05

Alarm Management & Human Factors

EEMUA 191 / ISA-18.2 aligned alarm rationalisation, HMI design, operator cognitive workload analysis, and performance KPI monitoring.

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06

Design Engineering & SCADA

Full-lifecycle PLC/DCS/SIS architecture, SCADA software development, cause & effects logic, FAT/SAT, and legacy control system migration.

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07

Systems Engineering & System Assurance

Requirements traceability, hazard analysis, V&V strategy, safety/assurance cases, configuration management, and independent technical review — from concept through to operational evidence.

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Deep Expertise.
Measurable Outcomes.

OTONUS delivers end-to-end cybersecurity programs across IT and OT environments, aligning IEC 62443, NIST CSF, and ACSC Essential Eight to the specific risk profiles of operational technology. We bridge the gap between corporate IT security and safety-critical OT networks — protecting availability, integrity, and safe operation.

Key Capabilities

  • OT/ICS security assessments — zone & conduit modelling, asset inventory, architecture review
  • IEC 62443 gap analysis, risk assessment, and security level targeting
  • Network segmentation design, DMZ architecture, and Purdue model alignment
  • Patch management strategy and vulnerability management for legacy OT environments
  • SOC integration for OT-aware threat monitoring
  • Incident response planning, playbooks, and tabletop exercises
  • Governance, policy uplift, and CSMS implementation
  • IT/OT convergence strategy — unified risk posture with segregated controls

Deliverables

  • OT Cybersecurity Risk Assessment
  • IEC 62443 Compliance Roadmap
  • Network Architecture Design
  • Security Management System
  • Incident Response Playbooks
Outcome: Quantified risk reduction, defensible compliance posture, and resilient OT operations protected against modern cyber threats.

OTONUS provides independent and embedded functional safety engineering across the full SIS lifecycle — from hazard identification and SIL determination through to design, verification, and operational validation. Our approach integrates seamlessly with process safety management and assurance frameworks.

Key Capabilities

  • HAZOP, LOPA, and SIL determination (IEC 61511) — risk-based and consequence-informed
  • SIS conceptual, basic, and detailed design to SIL 1–3 requirements
  • SIL verification — PFD/PFH calculations, architectural constraints, CCF analysis
  • Safety requirements specification (SRS) and functional safety plans (FSP)
  • Factory and Site Acceptance Testing (FAT/SAT) procedures and execution
  • Functional Safety Assessment (FSA) — Phases 1 through 5
  • Management of change (MOC) review for SIS modifications
  • Competency frameworks, training, and operator qualification

Deliverables

  • SIL Determination Study (LOPA)
  • Safety Requirements Specification
  • SIL Verification Report
  • Functional Safety Assessment
  • MOC Safety Review Protocol
Outcome: Defensible SIL compliance, reduced spurious trip rates, and full lifecycle traceability from hazard to validated protection.

OTONUS engineers operational resilience for high-availability assets by combining resilience metrics, barrier-based thinking, reliability engineering, and abnormal situation management. We apply scenario stress-testing, weak-signal detection, and data-driven leading indicators to reduce exposure to cascading events and latent conditions.

Key Capabilities

  • Resilience diagnostics — technical and organisational control assessment
  • Barrier health frameworks — identification, assessment, and performance monitoring
  • Compound failure scenario modelling — including cascading and latent conditions
  • Reliability-centred maintenance (RCM) and consequence-driven asset strategies
  • Weak-signal detection systems and leading indicator programme development
  • Abnormal situation management (ASM) design
  • Escalation pathway design — control, management, and emergency response integration
  • Data-driven resilience KPIs aligned to real operating envelopes

Deliverables

  • Resilience Diagnostic Report
  • Barrier Health Framework
  • Escalation Pathway Design
  • Leading Indicators Dashboard
  • Improvement Roadmap
Outcome: Measurable uplift in continuity, maintainability, and safe performance under pressure — with reduced latent failure exposure.

OTONUS integrates IIoT, edge–cloud architectures, digital twins, and advanced analytics with rigorous safety, cyber, and governance controls. We build human-centred, explainable, and resilient digital operations — where operators and engineers collaborate with decision-support systems that are transparent, auditable, and safety-aligned.

Key Capabilities

  • Sensor strategy, historian integration, and event streaming — robust data foundations
  • Digital twin development — physics-informed, data-driven, and hybrid models
  • Operational intelligence — OEE, reliability, energy and emissions dashboards
  • Edge–cloud architecture design for OT data with latency and security constraints
  • IIoT platform evaluation, selection, and deployment
  • Industry 5.0 human-centred design — explainable AI, operator collaboration
  • Interoperable, vendor-agnostic solutions that scale across sites
  • OT lifecycle sustainability — performance, security, and governance through-life

Deliverables

  • Digital Transformation Strategy
  • IIoT Architecture Blueprint
  • Digital Twin Specifications
  • OI/Analytics Dashboard
  • Governance & Lifecycle Plan
Outcome: Faster fault diagnosis, reduced operational variability, safer autonomy, and higher asset utilisation.

OTONUS modernises alarm systems to reduce nuisance alarms, prevent alarm floods, and improve response quality during abnormal situations. Our methodology aligns to EEMUA 191 / ISA-18.2 while embedding industrial human factors engineering to address operator workload, attention, cognition, and interface clarity.

Key Capabilities

  • Alarm philosophy development, rationalisation, and prioritisation programs
  • Alarm flood analysis, shelving governance, and KPI benchmarking
  • HMI/HF design — console layout, display hierarchy, situational awareness
  • Consequence-based alarm limits and meaningful message design
  • Operator task analysis (OTA) and cognitive workload assessment
  • Critical alarm identification and SIS alarm segregation
  • Continuous alarm performance monitoring and analytics platforms
  • Scenario-based training and operator interface qualification

Deliverables

  • Alarm Philosophy Document
  • Alarm Rationalisation Study
  • HMI/HF Design Review
  • Performance KPI Framework
  • Training & Competency Plan
Outcome: Stronger situational awareness, fewer process upsets, and safer, more stable operations with demonstrable risk reduction.

OTONUS delivers full-lifecycle design engineering and SCADA software development for complex industrial control environments. We combine rigorous systems design with deep OT domain expertise to produce control architectures, HMI solutions, and SCADA applications that meet safety, performance, and maintainability requirements.

Key Capabilities

  • Control system architecture design — PLC, DCS, ESD, F&G and hybrid platforms
  • SCADA software development — configuration, scripting, graphics, and integration
  • Cause and effects matrix development, logic and sequence design
  • SIS/BPCS interface design — independence, bypasses, and override management
  • Control narrative and Functional Design Specification (FDS) authoring
  • Factory Acceptance Testing (FAT) — test script development and execution
  • Legacy control system migration — brownfield risk and cutover planning
  • SCADA cybersecurity hardening and OT network integration design

Deliverables

  • Control System Architecture
  • SCADA Application Design
  • Functional Design Specification
  • FAT/SAT Test Documentation
  • Migration & Cutover Plan
Outcome: Reliable, secure, and maintainable control systems delivered on-scope — from design through to commissioned, verified operation.

OTONUS provides defensible system assurance for complex, integrated assets — linking requirements, hazards, controls, verification, and operational evidence into a single traceable assurance narrative. Our framework unifies systems engineering, functional safety, operational safety, and OT cybersecurity to manage emergent risk across interfaces, upgrades, and through-life changes.

Key Capabilities

  • Requirements engineering — elicitation, specification, decomposition, and traceability
  • Hazard and risk analysis — FMEA, FTA, STPA, barrier integration with safety cases
  • V&V strategy development — test plans, acceptance criteria, and evidence management
  • Safety/assurance case development and independent review (Goal Structuring Notation)
  • Configuration management and change impact assessment
  • Digital traceability — requirements to evidence, accelerating approvals
  • Interface management — emergent risk across system and organisational boundaries
  • Independent technical review and audit-ready artefacts

Deliverables

  • System Requirements Specification
  • Assurance Case (GSN/CAE)
  • V&V Strategy & Test Plans
  • Configuration Baseline
  • Change Impact Assessment
Outcome: Higher confidence at gates, lower integration risk, and demonstrable compliance — without slowing delivery velocity.

Where Engineering
Rigour Meets Operational Reality

OTONUS is a specialist industrial and technology consultancy serving high-hazard and capital-intensive industries including oil & gas, mining, energy, utilities, and advanced manufacturing.

Our multidisciplinary teams bring rigorous engineering discipline, deep domain expertise, and a structured methodology to every engagement — from strategy through to execution and ongoing assurance.

We do not separate safety from cyber, or resilience from digital transformation. Our value is in the integration — delivering solutions that hold together under the real conditions your assets face.

Industries We Serve

Oil & Gas Mining & Resources Energy & Utilities Advanced Manufacturing Water & Wastewater Chemicals & Petrochemicals Defence & Infrastructure

Standards & Frameworks

IEC 61511Functional Safety – SIS
IEC 61508Functional Safety – E/E/PE
IEC 62443OT Cybersecurity
ISA-18.2Alarm Management
NIST CSFCyber Framework
EEMUA 191Alarm Systems

Built Different.
For a Reason.

Integrated Discipline

Safety, cyber, resilience and digital — unified under a single engineering team and methodology. No handoffs, no gaps.

Operational Credibility

Our engineers have operated in and alongside the facilities we design and assure. No disconnect between theory and practice.

Standards Depth

Deep expertise in IEC 61508, 61511, 62443, ISA-18.2, NIST CSF — applied pragmatically to your risk context, not academically.

Evidence-Driven

Every recommendation is traceable to data, risk context, and operational reality — audit-ready by design, not afterthought.

Human-Centred

Human factors, operator interface design, and organisational capability embedded in every technical solution we deliver.

Delivery Focused

We produce executable roadmaps and tangible artefacts — not reports that sit on a shelf. Outcomes, not outputs.

Ready to Strengthen Your Operations?

Talk to us about your program. We'll identify where OTONUS can deliver the most impact — quickly and credibly.

Let's Talk About
Your Program

Whether you have an immediate need or are planning ahead, our team is ready to help you identify the right approach and the right level of engagement.

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