What Is Operational Technology Security?

Operational technology (OT) refers to the hardware and software systems responsible for controlling and managing industrial processes. These processes can include manufacturing, transportation, energy, and communication systems. As OT continues evolving and integrating with information technology (IT), the need for operational technology security has become increasingly important.

OT security protects the physical assets and processes of these industries’ operational technology (OT) systems. Unlike traditional IT systems that handle data and information processing, OT systems control physical equipment such as machinery, sensors, valves, alarms, and other devices used in industrial environments.

Operational technology (OT) and its importance in industrial settings

Operational technology (OT) refers to the hardware and software systems used to monitor and control physical processes in industries such as manufacturing, energy production, transportation, and more. It includes devices, sensors, networks, and applications used for industrial automation, data collection, and real-time decision-making.

The importance of operational technology in industrial settings cannot be overstated. OT plays a critical role in keeping up with these advancements while ensuring smooth operations. The adoption of OT has steadily increased in various sectors over the years as it offers a wide range of benefits.

Growing need for OT security in the age of digital transformation

The growing reliance on OT systems means they are now critical components of our essential services, from power grids and transportation systems to manufacturing plants and healthcare facilities.

This convergence between operational technology and information technology has created a significant challenge for organizations:

• How can they secure their OT environments against cyber threats without disrupting critical processes or compromising safety?
• With more sophisticated attacks targeting these hybrid networks, how do businesses prioritize OT security as part of their cybersecurity strategy? 

What is Operational Technology Security?

Operational Technology Security is a set of procedures and tools to protect critical infrastructure from cyber threats targeting industrial control systems. These threats could put lives at risk or cause severe damage to essential services such as power plants, water treatment facilities, transportation networks, and more. As modern OT systems become more connected and accessible through wireless networks or the internet, they are exposed to potential attacks from hackers who aim to disrupt operations by gaining unauthorized access or causing system malfunctions.

Operational Technology Security’s primary goal is to ensure the availability, integrity, and confidentiality of all OT assets. It also involves implementing measures to safeguard against unauthorized access or misuse of assets within an industrial environment.

The concept of OT security

Operational technology (OT) security refers to the measures and practices used to safeguard industrial control systems (ICS) and other critical infrastructure from cyber threats. In today’s digital age, industries such as energy, manufacturing, transportation, and healthcare heavily rely on interconnected devices and networks to control their processes.

OT security revolves around protecting these critical systems and preventing unauthorized access or manipulation by malicious actors. Unlike traditional IT systems, which prioritize data confidentiality, OT focuses more on availability and system integrity. A successful attack on an ICS can lead to operational downtime, physical damage to equipment, financial loss, and even harm to human life.

Difference between OT and IT security

OT (Operational Technology) and IT (Information Technology) are two types of technology that play an essential role in today’s digital world. While they share some similarities, they also have significant differences, especially regarding security.

OT security primarily protects physical assets such as machinery, equipment, and processes. These systems monitor and control industrial operations in sectors such as manufacturing, energy, transportation, and healthcare. IT security deals with safeguarding data assets transmitted through computer networks or stored on electronic devices.

One key difference between OT and IT security is their respective goals. OT security aims to ensure that critical infrastructure functions effectively without any interruptions or damages caused by cyber threats. This includes preventing accidents that could affect public safety or disrupt essential services.

The Importance of OT Security

Businesses must focus on the security of their information technology (IT) and operational technology (OT) systems. OT refers to the hardware and software that controls physical processes in industries such as manufacturing, energy, and transportation. These systems are responsible for the smooth running of critical infrastructure, and any vulnerabilities or breaches can have severe consequences.

The importance of OT security lies in protecting these critical infrastructure systems from cyber threats. With an increasing number of connected devices, often called the “Internet of Things” (IoT), there is a higher risk of cyber attacks targeting OT systems.

Risks associated with unsecured OT systems

Unsecured operational technology (OT) systems can present numerous risks and vulnerabilities to individuals and organizations. OT systems are used in various industries, such as manufacturing, energy, transportation, and healthcare, to manage critical processes and infrastructure. These systems are often connected to the internet or other networks for remote monitoring and control, making them susceptible to cybersecurity threats.

The primary risk associated with unsecured OT systems is the potential for cyber attacks. A successful cyber-attack could have severe consequences as these systems control essential functions in critical infrastructure, such as power grids and water treatment plants. Attackers may exploit vulnerabilities in unsecured OT systems to gain unauthorized access or disrupt operations, leading to service disruptions or even physical damage.

Examples of potential consequences of OT security breaches

Operational technology (OT) security breaches can have a wide range of consequences, from minor disruptions to critical failures that pose serious threats to an organization’s safety and productivity. Following are some examples of potential consequences of OT security breaches.

• Production Downtime: Production downtime is one of the most immediate and visible consequences of an OT security breach. In 2018, a cyber-attack on a pharmaceutical company’s industrial control systems caused production downtime for several weeks and led to significant revenue losses.
• Financial Losses: In addition to production downtime, OT security breaches can also result in financial losses for organizations. This includes not just the direct costs associated with recovering from the incident but also indirect costs such as reputational damage and legal fees. For example, the 2017 NotPetya ransomware attack on shipping giant Maersk cost them approximately $300 million in lost revenue and recovery expenses.
• Safety Risks: The consequences of OT security breaches are not limited to financial losses; they can pose serious safety risks for employees and consumers. For example, the Stuxnet worm attack on Iran’s nuclear program was explicitly designed to sabotage its centrifuge operations by causing physical damage.

Common OT Security Challenges

The need for operational technology (OT) security has become more pressing as the world becomes increasingly reliant on technology. OT refers to the systems and devices used in industrial or critical infrastructure settings, such as power plants, transportation systems, and healthcare facilities. These systems are becoming more connected and digitized, making them vulnerable to cyber-attacks. The most common challenges faced in ensuring OT security:

Legacy systems and outdated technology

Legacy systems and outdated technology, also known as legacy technology, refer to older computer hardware or software still in an organization despite being superseded by newer versions. Due to their lack of compatibility with modern technologies and the accompanying security risks, these legacy systems and technologies are often seen as a hindrance to progress and security for businesses.

One of the significant challenges organizations face with legacy systems is their vulnerability to cyber-attacks. Outdated technology typically needs more security features to protect against increasingly sophisticated cyber threats.

Lack of visibility and asset management

One of the significant challenges facing operational technology (OT) security is the need for more visibility and asset management. This issue refers to organizations’ inability to have a complete understanding of their OT network and assets, which can leave them vulnerable to cyber threats. OT networks often consist of complex systems responsible for managing critical infrastructure such as power grids, transportation systems, water treatment facilities, and more.

The first aspect of this challenge is the need for greater visibility over all devices connected to the network. Organizations usually still need a comprehensive inventory or map of their OT devices, which makes it difficult for them to monitor network activities or identify potential vulnerabilities.

Convergence of IT and OT networks

The convergence of IT and OT networks, also known as IT/OT integration, refers to merging information technology (IT) and operational technology (OT) systems within an organization. This integration has become increasingly common in today’s digital landscape as companies seek to streamline processes and increase efficiency by connecting their traditional OT systems with modern IT infrastructure.

OT systems have been isolated from the internet and other external networks for security purposes. These systems typically control physical equipment such as industrial control systems (ICS), supervisory control and data acquisition (SCADA) systems, and manufacturing execution systems (MES).

Human factors and insider threats

Human factors and insider threats play a crucial role in operational technology security. Insider threats refer to the potential risks or vulnerabilities that arise from the behavior, actions, or negligence of individuals within an organization. These factors are inherently difficult to control and can lead to serious consequences if not addressed properly.

One of the main reasons for human-related threats is employees’ need for more awareness and understanding of security protocols. Employees may often unknowingly violate security policies, such as sharing passwords or clicking on suspicious links, which can open doors for cyber attacks.

Key Components of an Effective OT Security Strategy

An effective OT security strategy is crucial in ensuring the protection and proper functioning of operational technology systems (OTs). These critical infrastructures, such as industrial control systems and other devices in manufacturing, oil and gas, energy, transportation, and healthcare, have become increasingly vulnerable to cyber threats.

Asset inventory and management

Asset inventory and management are crucial aspects of operational technology security. They refer to the process of identifying, tracking, and managing all assets that make up an organization’s operational technology infrastructure. This includes physical assets such as machinery, equipment, and facilities, as well as digital assets like software programs and network devices.

The first asset inventory and management step are creating an accurate inventory list. This involves compiling a comprehensive list of all operational technology assets within an organization. The list should include location, ownership, specifications, maintenance history, and other relevant information.

Network segmentation and access control

Network segmentation and access control are essential components of operational technology security. They refer to dividing a network into smaller subnetworks, or segments, based on specific criteria such as function, location, or user group. This allows for more targeted and granular security measures to be applied to different network parts.

One of the main reasons for implementing network segmentation is to limit access to critical systems and data. By creating separate segments for sensitive assets, organizations can better control who has access to them and can monitor any suspicious activity more closely.

Continuous monitoring and threat detection

Continuous monitoring and threat detection are vital to operational technology (OT) security. OT systems, which include industrial control systems (ICS), supervisory control and data acquisition (SCADA) systems, and other critical infrastructure, are vulnerable to cyber threats due to their interconnectedness and reliance on digital technologies.

One key challenge for OT security is the lack of visibility into these complex and diverse networks. Unlike traditional IT networks, where everything is centralized and easily monitored, OT environments are decentralized, with multiple devices connected across wide geographical areas.

Incident response and recovery planning

Incident response and recovery planning are critical aspects of operational technology (OT) security. OT systems are more vulnerable than ever to cyber attacks and other disruptive incidents.

Incident response planning primarily focuses on minimizing the impact of a cybersecurity incident on an organization’s operations, assets, and reputation. This involves having a clear understanding of the different types of threats that may target OT systems and identifying potential vulnerabilities within the system.

Employee training and awareness programs

Employee training and awareness programs are essential aspects of operational technology (OT) security. In any organization, employees play a crucial role in ensuring the safety and security of operational technology systems. It is vital for companies to invest in these programs to educate their staff on proper procedures and protocols for securing OT.

The primary purpose of these programs is to equip employees with the necessary knowledge and skills to identify potential cybersecurity threats and respond effectively to them. With the increasing complexity of OT systems and the ever-evolving nature of cyber threats, regular training is critical for employees to stay up-to-date with the latest security practices.

Best Practices for Implementing OT Security

As Operational Technology (OT) continues to grow and evolve in various industries, strong security measures are becoming increasingly important. OT systems are vital for functioning critical infrastructure such as energy, transportation, and manufacturing, making them prime targets for cyber attacks:

Conduct regular risk assessments

Regular risk assessments are essential to maintaining operational technology (OT) security. A risk assessment is a process that analyzes potential threats to an organization’s assets and evaluates the likelihood and impact of those risks occurring.

• Identifying Vulnerabilities: Risk assessments help identify potential weaknesses and vulnerabilities in an organization’s OT systems. These include outdated software, misconfigured devices, or unsecured connections that malicious actors could exploit.
• Prioritizing Risks: By conducting a risk assessment, organizations can prioritize which risks require immediate attention based on their likelihood and impact on operations.
• Compliance Requirements: Many industries have specific regulations for OT security, such as NERC-CIP for the energy sector or FDA guidelines for healthcare facilities. Regular risk assessments ensure compliance with these requirements, avoiding penalties and legal consequences.

Implement defense-in-depth strategies

Implementing defense-in-depth strategies is crucial to operational technology (OT) security. It involves layering multiple security measures to protect critical assets and systems from cyber threats. This approach ensures that even if one layer of defense fails, other layers are in place to prevent a successful cyberattack.

The first step in implementing defense-in-depth strategies is to conduct a thorough risk assessment of the OT environment. This assessment will help identify potential vulnerabilities and establish the level of risk associated with each asset or system. A risk assessment should be an ongoing process as new technologies and threats emerge continuously.

Establish secure remote access protocols

The rise of digitalization in the operational technology (OT) sector has brought countless benefits but also significant security risks. With the increased use of remote connections and internet-based systems, establishing secure remote access protocols has become essential for safeguarding OT systems against cyber threats.

Secure remote access refers to the ability to connect to a network or device from a different location using secure channels such as virtual private networks (VPNs), encryption methods, and multi-factor authentication.

Develop and maintain security policies and procedures

Developing and maintaining security policies and procedures are crucial to operational technology security. These policies serve as guidelines for organizations to protect their OT assets, systems, and networks from potential cyber threats. They outline the necessary measures to be taken by companies for a proactive approach towards safeguarding their operational technology infrastructure.

Creating an effective security policy begins with thoroughly understanding the organization’s operations, assets, and potential vulnerabilities. This involves identifying critical assets such as control systems, sensors, equipment, and networks that could have significant consequences if compromised or disrupted.

Collaborate with vendors and partners on security initiatives

Collaborating with vendors and partners is crucial for securing operational technology (OT) systems. As OT systems become more interconnected, the risks and vulnerabilities also increase. Collaboration between different vendors and partners is essential for effectively managing and mitigating these risks.

One of the main reasons for this collaboration is to ensure that all components of an OT system are secure. Vendors provide various products and solutions used in OT systems, such as industrial control systems, sensors, or network devices.

Emerging Trends in OT Security

As technology continues to advance rapidly, so do the threats against it. The rise of connected devices and intelligent systems has led to increased operational technology (OT) use in various industries, such as manufacturing, utilities, and transportation. With this increased connectivity also comes vulnerability to cyberattacks.

AI and machine learning in threat detection

AI (artificial intelligence) and machine learning have revolutionized threat detection in operational technology (OT) security. As technology continues to advance, so do the methods hackers use to gain access to sensitive systems and data. Traditional threat detection methods, such as rule-based systems and signature-based approaches, are no longer sufficient in combating the constantly evolving threats faced by OT systems.

With the help of AI and machine learning, OT security teams can now proactively detect and respond to threats more efficiently than ever before. These technologies utilize algorithms that can learn from data and identify patterns or anomalies that may indicate a potential threat.

Cloud-based OT security solutions

Cloud-based OT security solutions use cloud computing technology to secure operational technology infrastructure. This includes devices, networks, and systems used in critical industries such as manufacturing, transportation, energy, and healthcare.

One of the main advantages of cloud-based OT security solutions is their scalability and flexibility. As organizations adopt new technologies and expand their operations, more than traditional on-premises security measures may be needed to keep up with the changing landscape. Cloud-based solutions offer the ability to scale up or down based on business needs without requiring physical upgrades or changes.

Zero trust architecture for OT environments

Zero-trust architecture is a security model that assumes no user or device within a network can be trusted by default, even if they are inside the perimeter. This approach emphasizes continuous authentication of users and devices, strict access controls, and network segmentation. It is now gaining traction in OT (Operational Technology) environments to address the growing cybersecurity threats targeting industrial control systems.

OT networks control critical infrastructure such as power grids, transportation systems, and manufacturing processes. With their increasing digitization and connectivity, these systems have become vulnerable to cyber attacks that can have catastrophic consequences for public safety and national security.

Case Studies:

Case Study 1: Securing a Power Grid’s Operational Technology (OT) Environment

Industry: Energy and Utilities

Challenge:
A national power grid operator faced escalating risks of cyber threats targeting its Operational Technology (OT) systems. These systems managed critical infrastructure, including electricity distribution and load balancing. With increasing reports of ransomware attacks on utilities worldwide, the operator sought to secure its OT environment without disrupting operations.

Solution:

• Implemented a segmented network architecture to isolate OT systems from IT networks, reducing attack vectors.
• Deployed intrusion detection systems (IDS) tailored for OT protocols like Modbus and DNP3.

Outcome:
The operator successfully thwarted multiple attempted ransomware attacks. Their proactive measures also earned compliance certifications for critical infrastructure security, enhancing stakeholder trust.

Case Study 2: Incident Response for a Water Treatment Facility

Industry: Public Utilities

Challenge:
A water treatment facility experienced a targeted cyberattack where an attacker tried to manipulate chemical levels in the water supply via unauthorized access to OT systems. The breach was detected late, creating potential health risks.

Solution:

• Immediately activated the incident response plan to contain the breach.
• Deployed multi-factor authentication (MFA) for all remote access points and applied zero-trust policies for vendor access.

Outcome:
The breach was neutralized before any harm occurred, and the facility implemented long-term measures to secure its OT infrastructure, restoring public confidence.

Case Study 3: Enhancing OT Security for a Manufacturing Plant

Industry: Manufacturing

Challenge:
A global manufacturer with interconnected OT and IT systems faced a rise in malware attacks targeting its programmable logic controllers (PLCs), risking production downtime and supply chain disruptions.

Solution:

• Deployed endpoint detection and response (EDR) solutions tailored for OT devices to detect anomalies in real-time.
• Implemented role-based access controls (RBAC) to limit user access to critical OT systems.

Outcome:
The manufacturer saw a 90% reduction in security alerts from its OT systems and significantly improved operational continuity. The company reported no production downtime due to cybersecurity incidents in the following year.

Partner with SecureLayer7 for Comprehensive Operational Technology Security

Ensuring the security of Operational Technology (OT) systems is more critical than ever. These systems are the backbone of industries like energy, manufacturing, transportation, and healthcare, where disruptions can have significant operational, financial, and safety implications. SecureLayer7 specializes in providing tailored OT security solutions that safeguard your critical infrastructure against sophisticated cyber threats.

SecureLayer7 adopts a holistic approach to OT security, ensuring that your operational environment is protected without disrupting critical processes. With years of experience securing OT environments across various industries, SecureLayer7 understands the unique challenges of OT security. Partner with SecureLayer7 to safeguard your OT systems and ensure uninterrupted operations. With our expertise in identifying vulnerabilities, mitigating risks, and strengthening defenses, you can focus on driving innovation while we protect your critical infrastructure.

Book a meeting with Securelayer7 today to learn more.

Conclusion

Operational Technology (OT) security has emerged as a cornerstone of modern industrial operations. With the convergence of OT and IT systems, organizations face unprecedented challenges in safeguarding their critical infrastructure from evolving cyber threats. OT systems, once considered insulated from external attacks, are now vulnerable due to increased connectivity, digitization, and reliance on third-party vendors.

Ensuring OT security is not just about protecting equipment; it is about ensuring the availability, integrity, and safety of vital industrial processes. Whether in manufacturing, energy, transportation, or healthcare, OT systems are the backbone of operations that directly impact lives, economies, and public trust.

Organizations must remain vigilant, continually reassessing and evolving their security strategies to stay ahead of adversaries. By prioritizing OT security as part of their broader cybersecurity strategy, businesses can safeguard not only their operations but also the trust of their stakeholders.

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