Operational Technology (OT) is often a second thought in the average person’s mind. Many people do not understand how OT works, what is needed for it to operate or what would even happen if specific systems fail, yet it is involved in almost every aspect of our lives.
OT acts as the unsung hero, working quietly behind closed doors to power systems we rely on everyday. It controls and monitors important industrial processes, robots in factories, critical infrastructure like power grids, and even traffic lights, elevators, overseas water treatment, and ensures trains and pipelines function safely and efficiently. When handling these processes, unlike IT which deals with data and communication, OT places emphasis on physical processes, ensuring machinery, devices and infrastructure operating in real time.
OT systems were originally designed to run in isolation. Security was an afterthought; their central focus was uptime, precision and safety. They are often “air-gapped” – physically isolating a computer or network from other networks to prevent unauthorized access and data breaches, with no internet access as the end-all be-all for solutions. However, as companies become more aware of risks and as attacks flood headlines, they understand the need to undergo a digital transformation to incorporate security in all aspects of operation.
This security focused IT/OT convergence brings efficiency, but also exposes decades-old systems to a growing range of cyberthreats. Unlike a hacked email or stolen database, a successful OT attack can have immediate, real-world consequences: halted production, equipment damage, environmental disasters, or even put human lives at risk.
Whether it is Stuxnet’s sabotage of the Iranian nuclear facilities, or the Russian attack on the Ukrainian Power Grid, or the TRITON malware, which targeted safety systems in Saudi’s petrochemical plant, these are not isolated incidents. They reflect a shift in the threat landscape, where attackers are actively targeting OT systems. This means that a single vulnerability could trigger widespread devastation. To better understand the scale of these threats and how organisations can respond effectively, let’s examine their core aspects.
Understanding Operational Technology
Operation Technology refers to the hardware and software used to control and monitor important industrial processes, critical infrastructure and other physical devices in industrial environments. These networks are vital for the proper functioning of industries like manufacturing, power generation and transportation, among others, in our society.
Key Components of Operational Technology
- Control Systems
- Sensors
- Networking Devices
- Actuators
- Programmable Logic Controllers
- Human-Machine Interfaces
- Distributed Control Systems
- Supervisory Control and Data Acquisition (SCADA) systems
- Industrial Control Systems
- Remote Terminal Units
How does it differ from IT, IoT and IIoT?
OT systems were primarily designed to interact directly with the physical systems and processes. In contrast, Information Technology (IT), the Internet of Things (IoT), and the Industrial Internet of Things (IIoT) operate within digital networks to manage, collect, analyze, and transmit electronic data.
IT refers to the use of computers, servers, software, and networks to process, store, and transmit digital information. It supports business operations, communications, and data management.
IoT refers to the growing network of everyday interconnected physical objects connected to the internet. These devices can collect, send, and receive data over wireless IT networks, through the use of data centers, with minimal human input. They range from smart lightbulbs, wearables, to healthcare equipment and smart city infrastructure.
IIoT is a subset of IoT, but refers to the use of smart sensors used in industrial sectors such as manufacturing, energy, and utilities, to connect devices and other industrial equipment to the internet. When working alongside OT, IIoT plays a key role in increasing manufacturers’ speed of processing data since they are processing data closer to the source, improving operational efficiency, supporting informed business decisions, and increasing overall plant productivity.
How does the Operational Technology Environment Traditionally Operate
Traditionally, the OT environment was designed on the pillars of availability, safety and reliability. In this domain, systems run 24/7, controlling sensitive operations where just a few seconds of downtime could lead to massive loss in revenue, physical damages to systems, or safety hazards. As a result, OT systems prioritised being predictable and stable.
Protection for these environments includes air-gapping. This is physically isolating the OT system from other parts of the network and the internet. This approach is simple, but it provides security through separation. In contrast, it also means that many OT systems remain unpatched, outdated and difficult to monitor from remote locations. This issue is often exacerbated, particularly in these systems, as they are made to have long lifecycles, where equipment and machinery are expected to run non-stop for 10-30 years. This also leads to the creation of legacy system infrastructures and proprietary protocols that were never designed with modern cybersecurity best practices in mind. As a result, applying updates or patches can be risky and disruptive, so they are often avoided altogether.
This avoidant strategy may have worked in the past, but as OT systems become more interconnected to digital networks, the strict lines that divide OT, IT, IoT, IIoT also begin to blur, enabling smarter operations, remote access and real-time analytics creates new challenges for security, monitoring and governance without the benefit of typical traditional IT protections. The result is a growing attack surface in environments that are often poorly equipped to handle it.
Key Operational Technology Security Challenges
Legacy Systems
As previously mentioned, many OT systems are decades old. They therefore are outdated and lack many modern security features. One may think that simply replacing the older systems with new security-focused alternatives would solve this problem but in practice, this approach is very expensive and would require unacceptable levels of downtime.
These systems suffer from:
- Well-Known Vulnerabilities: Many systems are well-documented attacks and how to carry them out, making them easy and attractive targets for attackers.
- Inherent Compatibility Issues: Older systems aren’t built to support modern security solutions like encryption, multi-factor authentication, access control etc
- Limited Support: As vendors continue to create new products and solutions, they often discontinue support for older systems, thus creating a situation where you may find yourself forced to rely on pricey custom patches or niche expertise
Compliance Regulation
With increased awareness of the importance of security in all aspects of business operations, many organisations are now under increased pressure to comply with stricter regulatory compliance that varies across IT and OT environments. In these spaces, regulatory bodies place emphasis on implementing specific security controls to protect critical infrastructure and ensuring systems run continuously, as any disruptions can have severe safety, environmental or economical consequences. In IT environments, compliance focuses on data and privacy protection in mind, while OT compliance enforces solutions that address real-word safety and reliability risks.
Supply Chain Risk
This is a dangerous and difficult-to-control threat in OT environments. This can be seen from real-world attacks like the 2020 Solarwinds attack or the 2023 Okta breach. A mistake made by a trusted provider – being infiltrated, had a ripple effect across thousands of organisations world wide.
This highlights that even if organisations have their own defences implemented, compromised technologies along the supply chain can severely impact customers, beyond their control. This issue is also exacerbated, as many companies depend on third-party vendors for specialized solutions, including monitoring systems, control software, and even security tools adapted for OT use. If one of these vendors is compromised, attackers could gain indirect access to critical systems
Constant System Availability is Essential
Industrial operations and facilities are built on the principle of continuous operations. Uptime is everything. These include factories, energy grids, transportation systems and water plants, which are designed to operate continuously.
Cyberattacks or other security incidents can trigger disruptions, leading to cascading effects. For example, service outages, production delays, financial loss and in severe cases, risks to workers’ safety or the safety of the general public. Therefore, many organisations are unable to take these systems offline for updates, and are forced to leave vulnerabilities unpatched for longer than they’d like, making OT environments particularly easy targets for attackers. Security teams thus have to walk the fine line between strengthening defences and maintaining uptime.
Sophisticated Attacks
More complicated attacks are becoming the norm in the OT security attack landscape, mirroring developments in IT security. AI-based tools make it even easier for attackers to learn the skills needed to attack specific legacy softwares. They do so by allowing the attacker to automate reconnaissance, adapt existing malware in real time, and launch polymorphic attacks that are harder to detect, resulting in threats that are both more requests and more complex.
In OT environments, this creates significant vulnerabilities as they often rely on legacy systems. Especially as these systems were not built to withstand AI’s ever changing capabilities. Businesses are thus now burdened with the task of identifying these attacks quickly, but to also distinguish them from expected industrial processes, a skill that requires years of experience in detection skills, deeper operational awareness and how to use AI defensively to counter offensive AI usage.
Lack of Awareness
Another major vulnerability is a general lack of cybersecurity awareness among members of staff, especially regarding implementing secure OT system configurations. Many employees are not kept up to date on changes in the environment and they are inadequately trained to follow established security protocols, leaving them vulnerable to social engineering and other human-focused attacks. This gap enhances a weak link, as even the most advanced technical defences can be undermined by human error or manipulation.
Real World Operational Technology Incidents
Ukrainian Power Grid Attack:
Almost 10 years ago, in December 2015, Ukraine was hit by a major attack on its power grid, resulting in country-wide outages. Hackers were able to breach the OT systems using spear phishing emails and then used BlackEnergy, a malicious SCADA tool, to gain control of the systems to control the power systems and cut power supplied to many households.
The Colonial Pipeline Attack:
This attack took place in 2021, and stands as a clear example of the severe consequences of successful attacks on critical systems. The attackers used DarkSide ransomware to force the company to shut down its OT systems, disrupting nearly half of the East Coast of the United States fuel supply, which then triggered widespread shortages, panic purchases, and a surge in prices.
It is important to note that the attackers did not attack the other systems directly, but by breaching regular IT systems, it shows that the two systems are intertwined and shows how critical the need for strengthened security for critical infrastructure as cybersecurity breaches can have on essential services.
The Saudi Triton Malware Attack:
In 2017, the Triton malware, also known as Hatman or Trisis, was deployed across the Saudi Arabian petrochemical plant, specifically targeting the facility’s Safety Instrumented Systems (SIS). These systems are designed as a last line of defence to protect workers and equipment for dangerous conditions by shutting down operations in cases of emergencies.
The goal was to disable the safety mechanisms to potentially cause catastrophic physical damage, fires or explosions. Thankfully, this attack was unsuccessful due to the malware also inadvertently shutting down operations before the damage could be carried out. Despite the attack failing, this is a chilling demonstration of how cyberattacks could directly endanger human lives, not just data or business profits.
Ransomware Attack on Hydro:
The Norwegian aluminum giant Norsk Hydro was hit by the LockerGoga ransomware in 2019. LockerGoga is a malicious ransomware that was made to encrypt data stored on systems and that encrypted data is then used to blackmail users. The ransomware has spread across Hydro’s wide network, forcing plants to switch to manual operations, costing the company around $70 million in damages.
Best Practices for Securing Operational Technology
Periodic Testing
Periodic testing involves regularly assessing the security posture of OT systems to identify any vulnerabilities. This is connected both internally and externally, through vulnerability assessments, penetration testing and audits to ensure any identified risk is treated in a timely manner. This proactive approach helps mitigate risks, especially as OT networks become increasingly interconnected with IT systems.
Segmentation
Segmentation is a key security practice in OT that the cybersecurity team can employ to block attackers and unauthorized users. It reduces the attack surface, enhances visibility, and improves operational efficiency. They often use conduits like firewalls to precisely control data flow between the segmented zones, significantly limiting the lateral movement of attackers. Further, if an attack does take place, segmentation limits the damage that can occur.
Physical and Environmental Security
This includes buildings, gates, fences, keycard systems, biometric scanners, security guards, hard dogs, CCTV among many other infrastructure implemented to protect the OT physical environment from unauthorised access, tampering, theft, vandalism and any environmental hazards.
Access Control Systems
Enforcing strict access control to the OT systems is also a vital practice. This could be in the form of Role-Based Access Control (RBAC), least-privilege access, Multi-Factor Authentication (MFA); these measures limit access to only users who require it. This is a preventative measure that can block unauthorized access that could lead to security breaches.
Employee Training
Training should be tailored to specific systems, conducted on a regular basis, cover critical and current threats targeting OT systems, the best way to secure them and the importance of following security protocols. Furthermore, organisations should aim to foster a culture of open communication to encourage staff to report suspicious activity or potential weaknesses immediately. When members of staff thoroughly understand the risks, threats and common attack vectors, they are better equipped to detect potential attacks early on.
Threat Detection and Monitoring Tools
Threat detection and monitoring tools allow for quick identification of critical threats, and then isolating them before they can escalate into major incidents. In the context of OT environments, continuous monitoring focusing on cyber attacks and operational and industrial processes.
Final Thoughts
Operational Technology acts as the backbone for many industries needed to sustain modern society. From energy and transportation to manufacturing, water treatment and other critical infrastructure. Over the past few years, many incidents have occurred on these systems; ransomware attacks on pipelines and malware targeting safety systems, among other attacks, have shown that OT environments are no longer isolated from cyber threats. Attacks, whether successful or not, can result in operational disruption, financial loss, and most importantly, risks to human safety.
Organizations can no longer afford to treat OT security as a secondary concern, especially as they suffer from unique security concerns. Therefore, protecting these systems requires a deep understanding of how OT components work together with IT, and IIoT, awareness of unique security challenges, robust access controls, and comprehensive employee training. Security measures designed for typically IT systems alone are insufficient; each OT environment requires a tailored solution, capable of balancing safety, reliability and cybersecurity.
Your team shouldn’t wait for an attack to occur. The time to act is now. Organizations must proactively assess their OT environments, identify any vulnerabilities and implement strong security controls before a cyber incident forces reactive measures. By prioritizing security and fostering a culture of safety, you are not only protecting your systems but also protecting lives, communities and the continuity of essential services.
Taking the right proactive approach today can prevent catastrophic consequences tomorrow. Contact our team of experts today to assess your security posture and to implement proven strategies to safeguard your OT operation environment before it’s too late.
