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China’s state-sponsored hacking campaign, Volt Typhoon, highlights the advanced nature of cyber threats. Through small or home office (SOHO) routers, the attackers compromised the IT environments of U.S. critical infrastructure with one goal in mind—to make the lateral move to OT assets and cause disruption.
IT and OT security realms are becoming increasingly interconnected, and the need to secure both is critical. This comprehensive guide will help IT and OT professionals understand the intricacies of OT security, threats, emerging technology, frameworks, and how to build an OT infrastructure.
OT security, short for Operational Technology security, is the practice of safeguarding industrial control systems and the hardware and software that manage critical infrastructure. At its core, OT security aims to:
The House Committee on Homeland Security’s Cyber Threat Snapshot revealed that cyberattacks on critical infrastructure increased by 30% in 2023. This increase, combined with regulations on timely public data breach announcements, resulted in increased negative brand perception, decreased productivity, more revenue loss, and business-critical data loss.
Understanding threat actors’ diverse motivations and capabilities is crucial for effective cybersecurity, as these adversaries range from financially motivated cyber criminals to politically driven nation-state actors, and even insiders within the organization.
While the actors are the people who commit the crimes–and the attack vectors are the pathways. Cybercriminals exploit the following vector types to gain unauthorized access to systems and data:
The SANS 2024 State of ICS/Cybersecurity Report states that ransomware incidents decreased. Some of the most common attack vectors included compromised IT systems, spear-phishing attachments, removable media, cyber assets (i.e., vendor laptops), and public-facing application exploits.
The report also highlights that ICS/OT cybersecurity attacks impact the energy and manufacturing industries the most. The energy sector’s cautious adoption of cloud solutions due to regulatory frameworks like NERC CIP leaves it vulnerable to cyberattacks. Manufacturing’s reliance on operational technology leaves them vulnerable to attacks that can disrupt production lines and supply chains.
Understanding the importance of OT security is crucial for organizations managing critical infrastructure. Here are the key reasons why OT security matters, illustrated with real-world examples:
OT security breaches can lead to tangible harm.
Example: In 2021, a hacker attempted to poison the water supply in Oldsmar, Florida by remotely accessing the water treatment plant’s systems.
OT security incidents can result in massive financial losses.
Example: The 2017 NotPetya ransomware attack cost shipping giant Maersk an estimated $300 million in lost revenue.
OT systems are prime targets for nation-state attackers.
Example: The 2015 Ukraine power grid attack, attributed to Russian hackers, left 230,000 people without electricity.
Many industries face strict OT security regulations.
Example: The North American Electric Reliability Corporation (NERC) Critical Infrastructure Protection (CIP) standards mandate cybersecurity measures for the power grid.
While OT and IT security aim to protect digital assets, they have distinct priorities and approaches. For professionals working in these spaces, bridging the two is essential. Let’s dive into IT and OT security features like lifespans, patching practices, and more with examples.
Understanding the differences between OT and IT security is essential for effective OT security because it ensures that protective measures address the unique challenges of OT environments. OT systems often control critical infrastructure where safety and reliability are non-negotiable, and disruptions can have severe consequences. By recognizing how priorities like SRA differ from IT’s CIA model, professionals can develop strategies that minimize risks without compromising system performance or availability. This knowledge helps create security solutions that respect the constraints and demands of OT, ultimately protecting both the technology and the people who rely on it.
Organizations implementing OT security face several unique hurdles:
Outdated technology that’s difficult to update or replace
Challenges in taking systems offline for security updates
Standard IT security tools often ineffective in OT environments
Increased connectivity leading to greater vulnerability
Need for expertise in both cybersecurity and industrial processes
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The convergence of OT and IT is rapidly transforming industrial operations, but it also brings new security challenges. This section will discuss several emerging technologies and potential cyber threats.
Industrial IoT
The Industrial Internet of Things (IIoT) is an ecosystem of sensors, actuators, control systems, applications, and network equipment that work together to gather and analyze operational data.
While IIoT enables smart factories and predictive maintenance, it also coincides with the uptick of cyber threats against OT and ICS for the following reasons:
Cloud computing uses a network of remote servers hosted on the internet to store, manage, and process data.
While cloud services are scalable and cost-effective, their presence in OT environments can present a few security threats:
Artificial Intelligence (AI) uses computers to perform tasks in real-world environments, while machine learning (ML) is the technology that allows systems to see patterns, make decisions, and improve.
AI/ML technologies offer significant potential for enhancing OT threat detection and response, including:
Integrating AI/ML into OT environments introduces security risks like data poisoning, model theft, adversarial attacks, and lack of transparency. Attackers can manipulate training data, steal models for malicious use, or exploit vulnerabilities in AI systems to disrupt operations, cause physical damage, or compromise sensitive data. Lowering these risks requires robust data security, model protection, adversarial robustness, explainable AI, and secure integration practices.
Digital twins are virtual replicas or representations of a physical asset, system, or process. They use real-time data from sensors, devices, and other technology to replicate the original source’s behavior, performance, and condition.
Several security benefits of digital twins include:
A 5G network can provide high speed, low latency, and enhanced capacity needed to enable real-time data exchange. You can even use 5G to promote the remote control of OT systems.
Of course, there are security challenges that can accompany a 5G network:
Edge computing brings data processing and analysis closer to the source—minimizing latency and enhancing responsiveness.
However, challenges arise when it comes to securing a vast number of edge devices deployed in remote or harsh environments. Ensuring the confidentiality, integrity, and availability of the data processed at the edge can help your organization maintain its data privacy and securit
To effectively implement OT security, organizations should focus on these best practices:
Asset visibility creates a detailed inventory of all OT assets, including devices, hardware, software, and network connections. Maintaining an inventory creates the foundation of a strong OT security program by ensuring the safety and reliability of critical infrastructure, from power grids to water treatment plans and more.
Asset visibility benefits your organization by:
Like a blueprint helps builders understand a building’s structure, asset visibility provides a roadmap for your cybersecurity efforts.
Key principles with asset visibility are accuracy, completeness, and consistency. You need to maintain accurate and up-to-date information. This includes every device, software, and connection for when an emergency occurs and the data collection for the assets must remain consistent.
Here are a few steps to get started:
While gathering your inventory, it’s important to be mindful of your impact on operations. When possible, minimize disruptions to critical operations during data collection and inventory maintenance. You can solve for this by gathering inventory on off hours or days.
Integration with OT systems is another consideration. Make sure to choose tools and methods compatible with your existing OT systems and protocols.
Additional best practices with asset visibility include:
Network segmentation is the practice of dividing a network into smaller isolated zones. This strategy plays a crucial role in protecting critical infrastructure by minimizing the potential damage from cyberattacks and ensuring continued operations.
Network segmentation benefits your organization by:
If your OT network is a city, then network segmentation is the neighborhoods with controlled access points—making it harder for perpetrators to move and damage the network. Essentially, you divide your OT network into specific areas. Then, you can create customized security controls for each one based on its risk level and function.
Network segmentation’s key principles revolve around intentional access, security layers, regular review, and continued collaboration. Organizations should only grant necessary access to each segment and ensure multiple layers of security within each group. You’ll need to continuously assess and adjust segmentation based on your organization’s changing needs. Communication between IT and OT teams is critical to bridging the gap and keeping your organization safe.
Here are a few steps to get started:
When implementing network segmentation, you need to consider the operational impact and minimize disruptions to production processes during segmentation implementation.
It’s important that any implemented network segmentation does not negatively impact the performance of OT systems.
Additional best practices with network segmentation include:
Strict access control implements rigorous access controls and authentication measures to ensure only authorized personnel can access critical OT systems—using methods like authorization and role-based permissions. The overall goal is to minimize risk while maintaining operational safety and continuity.
Strict access control benefits your organization by preventing breaches, protecting critical infrastructure, and ensuring system reliability.
Think of strict access control like securing a vault. Only authorized personnel have keys; their activities are logged and monitored to ensure things go smoothly.
The core principle of strict access control is “least privilege,” meaning users only get the minimum access necessary to perform their roles.
Here are a few steps to get started:
Organizations must carefully balance the need for robust security with the requirements of their environment. While strict access control can lower the risk of cyber threats, you must also lower overly restrictive measures that decrease productivity and cause disruptions.
Additional best practices with strict access control include:
Vulnerability management identifies, prioritizes, remediates, and reports software misconfigurations within OT systems. This strategy is crucial because OT systems often run on legacy software with unpatched vulnerabilities, which makes them prime targets for cyberattacks.
By addressing these weaknesses, organizations can reduce the likelihood of system failures and protect critical infrastructure.
How Vulnerability Management Works
Think of vulnerability management as inspecting a bridge for cracks. If you find and address the cracks now, they won’t grow and result in the bridge’s collapse.
Here are a few steps to get started:
OT systems often cannot tolerate frequent updates or downtime, making traditional IT vulnerability management approaches unsuitable. Important factors include using tools designed for OT environments, aligning mitigation efforts with maintenance schedules, and involving OT operators in planning.
Best practices include:
Incident response planning involves preparing for and managing cybersecurity incidents to minimize their impact on OT systems. This strategy prevents minor incidents from escalating into significant disruptions through timely and effective responses. It also supports the broader goal of resilience, ensuring critical infrastructure can quickly recover from attacks.
Incident response planning is like a fire drill. When done effectively, everyone knows their role, and the organization can act quickly in a crisis.
To make incident response planning in OT environments effective, you need to provide a structured approach to detect, contain, and recover from cyber threats.
Here are a few steps to get started:
Challenges with incident response planning in OT environments include a lack of visibility into older systems and alignment between IT and OT security teams.
When building an effective incident response plan, OT security professionals need to consider the safety of physical processes, communicate clearly, and ensure the plan aligns with regulatory requirements.
Additional best practices include:
Security awareness training educates employees and contractors about cybersecurity risks in OT environments. It’s essential because human error is one of the leading causes of security breaches. By improving awareness, organizations can reduce risks like phishing attacks and accidental misconfigurations, break down silos, and improve cross-team communication.
Security awareness training is like driver’s ed—the learnings from the road enable new drivers to make safe decisions.
Here are a few steps to get started:
Challenges within the security awareness space include relevance for ensuring content is diverse for roles across organizations and addressing misconceptions about OT security.
To build effective security awareness, OT personnel must ensure their scenarios are OT-specific and their content reflects emerging threats. It’s also good to bring in leadership to encourage participation.
Additional best practices include:
Using hands-on exercises
Providing role-specific guidance
Reinforcing key concepts through ongoing learning
Secure remote access enables authorized personnel to access OT systems from offsite locations while protecting them from cyber threats. This is crucial as remote access is often needed for maintenance or troubleshooting, but unsecured access can expose systems to attacks. Properly implemented, it ensures both operational efficiency and system safety.
Secure remote access is like allowing a trusted mechanic into a restricted area—access is only granted to the right person for as long as necessary.
Here are a few steps to get started:
Step 1: Integrate a VPN into your security protocol.
Step 2: Implement strong authentication measures.
Step 3: Continue monitoring remote sessions.
Challenges with secure remote access include ensuring compatibility with legacy systems and balancing security with operational needs.
To continue lowering risk, OT personnel must secure their networks and endpoints. Best practices include:
Read the White Paper: Technology-Enabled Vulnerability Assessment
Discover how technology-enabled assessments prioritize security gaps and remediation, saving time and costs for industrial organizations.
Navigating the world of OT cybersecurity can be overwhelming due to the sheer number of different frameworks. Luckily, these frameworks offer guidance on building a strong security program. They cover both general OT security and industry-specific best practices. Some are mandatory regulations, while others are voluntary standards. Key frameworks include:
The NIST Cybersecurity Framework (CISF) provides guidelines for organizations to proactively manage cybersecurity risks, identify vulnerabilities, and effectively respond to incidents. Organizations can pair this broader framework alongside the niche NIST 800-53 catalog for a comprehensive OT security strategy.
A water treatment facility uses NIST CISF to improve its cybersecurity awareness training program. As a result, the employees are more educated about the risks of phishing attacks and engineering.
The Center for Internet Security Controls (CISC) is a prioritized list of cybersecurity best practices that help organizations protect their systems and data. Initially focused on IT environments, CIS now includes an OT version that addresses the unique challenges of industrial systems.
An energy plant uses vulnerability management controls to identify and address outdated firmware on critical equipment. The result of these efforts is enhanced visibility of OT assets and improved resilience against cyber threats.
NIST 800-53 provides a comprehensive catalog of security and privacy controls for industrial control systems. Organizations can use this technical framework alongside the broader NIST Cybersecurity Framework (CSF).
A manufacturing plant uses controls from the Identification and Authentication family to ensure that only authorized personnel can access critical systems.
The ISO 27000 series provides best practices for managing information security. Robust information security practices are crucial in OT environments because they help protect sensitive data often used by OT systems, provide flexibility on how to implement the standard and build a culture of security across your organization.
A manufacturing plant implements an information security management system based on ISO 27001 to identify vulnerabilities within its production line. They implement access control measures per ISO 27002 to restrict access to critical systems and data. Implementing both standards improves the plant’s security and reduces the risk of cyberattacks and data breaches.
IEC 62243/ISA 99 is a security standard designed explicitly for OT environments that provides a framework to protect industrial systems against cyberattacks.
A manufacturing plant implements IEC 62443 by defining security zones within its industrial network to isolate critical systems such as robots and programmable logic controllers (PLCs). This network segmentation helps limit the impact of potential cyberattacks by containing the spread of malware or other threats.
The plant also integrates security considerations into the development lifecycle of all new OT devices to ensure that security measures are built from the ground up. These actions result in enhanced system security, reduced attack surfaces, improved resilience to cyber threats, and enhanced compliance with relevant regulations and industry standards.
In this webinar, we will walk through an introduction to the overall standards and try to help make sense out of some of the alphabet soup of different terminology in a practical manner. We will also share practical experiences on addressing these standards and making meaningful progress in your overall ICS security maturity efforts.
OT personnel are caught in a balancing act between cyber threats, the merge of IT/OT security practices, and changing regulations. This heightened risk requires a comprehensive approach to OT security, mirroring the robust measures already implemented in IT environments.
Regulations like the TSA pipeline requirements and NERC-CIP are pushing organizations to know more, take action, and report in different ways. Adjusting to regulatory changes is often resource-intensive, proving difficult for OT environments with limited resources.
The most successful OT programs have a clear purpose, define success, and set expectations for communication. Here are a few tips to start protecting your OT environment:
Dive into this strategy in greater detail with this webinar:
The rise of ransomware attacks and stricter regulations (like the 2021 TSA guidelines) demand a proactive approach to securing critical infrastructure. This session with John Livingston will equip you to achieve compliance with OT regulations like vulnerability management, mitigate endpoint risks with practical controls for OT environments, and bridge the gap between IT security and OT needs. Learn how to effectively defend your industrial systems in today’s evolving threat landscape.
As the field of OT security continues to evolve, several key trends are shaping its future:
As cyber threats continue to evolve and target industrial systems, implementing robust OT security measures is crucial for protecting physical assets, ensuring operational continuity, and safeguarding public safety. This requires maintaining a comprehensive inventory of assets, conducting security tests, regularly monitoring for threats, and aligning with your IT team.
By understanding the unique challenges of OT security and implementing the strategies and frameworks outlined in this guide, organizations can build their resilience against cyber threats and ensure the integrity of their critical operations.
Ready to strengthen your organization’s OT security posture? Contact us now.
OT Security (Operational Technology Security) is the set of practices, technologies, and strategies specifically designed to protect the industrial control systems (ICS), SCADA systems, and other specialized hardware and software that control physical processes and operations.
OT security focuses on ensuring the safety, availability, and reliability of these systems, as disruptions can lead to physical damage, production loss, or even endanger lives.
It differs from IT security by prioritizing operational continuity and safety, and necessitates specialized knowledge of industrial systems and protocols.
IT security (Information Technology security) and OT security are both crucial for modern organizations, but they have distinct focuses and priorities.
Focus: Protects the confidentiality and integrity of data within business networks, servers, and user devices.
Main Threats: Malware, phishing attacks, data breaches, and unauthorized access.
Skills Required: Network security, data encryption, threat detection and response.
Focus: Ensures the availability, reliability, and safety of industrial control systems (ICS), SCADA systems, and the physical processes they manage.
Main Threats: Sabotage, operational disruptions, potential safety hazards, and cyber-physical attacks that can cause real-world damage.
Skills Required: Understanding of industrial protocols, processes, safety standards, and the potential consequences of cyberattacks.
OT security is more critical than ever due to:
Increased Connectivity: Industrial systems are increasingly connected to IT networks and the internet, expanding the attack surface.
Evolving Threats: Cyberattacks targeting OT are becoming more sophisticated and can have devastating real-world impacts.
Legacy Systems: Many OT environments rely on older technology with limited built-in security, making them easy targets.
Regulations: Growing government and industry regulations are mandating stronger OT security measures.
Key OT security challenges include:
Limited Visibility: Many organizations lack a complete inventory of OT assets, making it difficult to identify and secure all potential vulnerabilities.
IT/OT Gap: Differences in culture and priorities between IT and OT teams can hinder collaboration and effective security.
Patching Difficulties: Outdated OT systems may not support regular security patches, leaving them vulnerable.
Skill Shortage: Specialized skills for understanding and managing OT security risks are in high demand.
Essential best practices include:
Asset Identification: Develop a comprehensive inventory of all OT hardware and software.
Network Segmentation: Isolate OT networks from IT networks whenever possible to limit the impact of breaches.
Risk Assessments: Conduct regular risk assessments to identify and prioritize vulnerabilities.
Incident Response: Have a clear incident response plan for OT cyberattacks.
IT/OT Collaboration: Foster a culture of cooperation and shared responsibility for security.
Having the right tools is crucial for effective OT security. With increasing digitization, these tools play a pivotal role in safeguarding critical infrastructure. Essential OT tools and technologies include:
1. Asset Inventory: Tools that provide comprehensive visibility into all devices and systems within the OT environment.
2. Vulnerability Management and Risk Assessment: Solutions to identify weaknesses in OT systems and networks.
3. Patch Management: Tools to automate the process of deploying security patches.
4. Configuration Management: Tools to maintain control over OT system configurations.
5. OT/ICS SIEM (Security Information and Event Management): Systems for monitoring, detecting, and responding to security incidents.
6. Incident Response, Backup, and Restore Solutions: Incident coordination and data recovery tools.
You can find several OT security case studies in our resources section. They cover many of our solutions, and feature clients from several industries including chemical production, energy, power generation, and oil & gas.
Join Verve’s experts as they share key insights from 2024 and practical strategies to secure your OT environments in 2025. Don’t miss this exclusive webinar—reserve your spot now!