Cybersecurity for OT
Operational Technology (OT) cybersecurity protects the industrial control systems that run manufacturing operations from cyber threats. Unlike IT systems where confidentiality is paramount, OT security prioritizes availability and safety - production must continue, and people must be protected. As manufacturing systems become more connected through IIoT and Industry 4.0 initiatives, attack surfaces expand and threats increase. From ransomware disrupting production to nation-state attacks targeting critical infrastructure, OT cyber risks are real and growing. Professionals who understand both cybersecurity principles and industrial systems are essential for protecting manufacturing operations while enabling the connectivity that drives business value.
OT Cybersecurity Fundamentals
Understanding OT security context:
OT vs IT Security:
Different Priorities:
- IT: Confidentiality, Integrity, Availability (CIA)
- OT: Safety, Availability, Integrity, Confidentiality (SAIC)
- Uptime critical in OT
- Safety is paramount
Different Systems:
- PLCs, DCS, SCADA
- Long lifecycles (20+ years)
- Limited patching capability
- Legacy protocols
Different Environments:
- Physical processes
- Real-time requirements
- Harsh conditions
- Safety-critical operations
Threat Landscape:
Threat Actors:
- Nation states (sophisticated)
- Criminal organizations (ransomware)
- Hacktivists (disruption)
- Insiders (accidental and malicious)
Attack Types:
- Ransomware (most common)
- Targeted attacks (Stuxnet-style)
- Supply chain compromise
- Credential theft
Entry Points:
- IT/OT convergence points
- Remote access
- USB devices
- Third-party connections
Notable Incidents:
- Stuxnet (2010)
- Ukraine power grid (2015, 2016)
- Colonial Pipeline (2021)
- Manufacturing ransomware (ongoing)
Frameworks and Standards:
IEC 62443:
- Industrial cybersecurity standard
- Security levels
- Zones and conduits
- Comprehensive framework
NIST Cybersecurity Framework:
- Identify, Protect, Detect, Respond, Recover
- Risk-based approach
- Widely adopted
- Applicable to OT
ISA/IEC 62443:
- Industrial automation focus
- Security lifecycle
- Component and system security
- International standard
CIS Controls:
- Prioritized security actions
- IT-focused but applicable
- Starting point for many
Defense Strategies
Protecting OT environments:
Defense in Depth:
Multiple Layers:
- No single point of failure
- Assume any layer can fail
- Defense at every level
- Redundant controls
Network Segmentation:
- Separate IT and OT networks
- Zone model (Purdue model)
- DMZ for data transfer
- Firewalls between zones
Zones and Conduits:
- Group assets by function
- Define allowed communication
- Control data flows
- Minimize connections
Network Security:
Architecture:
- Air-gap where possible
- DMZ for necessary connections
- Industrial firewalls
- Unidirectional gateways
Monitoring:
- Network detection systems
- Anomaly detection
- Protocol-aware monitoring
- Logging and alerting
Access Control:
- Network access control
- VLANs and segmentation
- Jump servers for access
- Least privilege
Endpoint Security:
Hardening:
- Remove unnecessary services
- Disable unused ports
- Application whitelisting
- Configuration management
Patching:
- Risk-based approach
- Test before deploy
- Compensating controls
- Vendor coordination
Anti-malware:
- Where compatible
- Minimal performance impact
- Update challenges
- Alternative controls
Access Management:
Identity Management:
- Centralized where possible
- Role-based access
- Privileged access management
- Service accounts
Authentication:
- Multi-factor for remote access
- Strong passwords
- No shared accounts
- Audit trails
Remote Access:
- VPN with MFA
- Jump servers
- Session recording
- Time-limited access
Security Operations
Operating secure OT environments:
Asset Management:
Inventory:
- Know what you have
- Hardware and software
- Network connections
- Criticality assessment
Vulnerability Management:
- Regular assessment
- Risk-based prioritization
- Compensating controls
- Vendor coordination
Configuration Management:
- Baseline configurations
- Change control
- Drift detection
- Documentation
Monitoring and Detection:
Security Monitoring:
- Network monitoring
- Log collection
- SIEM integration
- Alert management
OT-Specific Tools:
- Industrial protocol detection
- Asset discovery
- Anomaly detection
- Vendors: Claroty, Dragos, Nozomi
Indicators of Compromise:
- Unusual traffic patterns
- Unauthorized changes
- Anomalous behavior
- External intelligence
Incident Response:
Preparation:
- Incident response plan
- OT-specific procedures
- Communication plans
- Testing and exercises
Response:
- Containment without disruption
- Forensics capability
- Recovery procedures
- Documentation
Challenges:
- Cant just shut down
- Limited forensics capability
- Safety considerations
- Production pressure
Recovery:
- Backup and restore
- Known-good configurations
- Phased recovery
- Validation procedures
Governance:
Policies and Procedures:
- OT security policy
- Access control procedures
- Change management
- Incident response
Risk Management:
- Risk assessment
- Risk acceptance process
- Continuous evaluation
- Executive visibility
Compliance:
- Regulatory requirements
- Industry standards
- Audit support
- Documentation
Career Development
Building OT cybersecurity expertise:
Career Paths:
OT Security Analyst:
Monitor and respond:
- Security monitoring
- Incident response
- Vulnerability assessment
- $70,000-$100,000
OT Security Engineer:
Implement security solutions:
- Security architecture
- Tool deployment
- Integration
- $90,000-$130,000
OT Security Architect:
Design security programs:
- Enterprise architecture
- Strategy development
- Standards
- $120,000-$170,000
ICS Security Consultant:
Advisory and assessment:
- Risk assessment
- Compliance
- Program development
- $100,000-$160,000
Skills Required:
OT Knowledge:
- Industrial control systems
- PLCs, DCS, SCADA
- Industrial protocols
- Manufacturing processes
Cybersecurity:
- Security fundamentals
- Network security
- Incident response
- Risk management
Unique to OT:
- IEC 62443
- OT-specific tools
- Safety considerations
- Availability focus
Certifications:
OT-Specific:
- GICSP (GIAC)
- GRID (GIAC)
- ISA/IEC 62443
General Security:
- CISSP
- Security+
- CISM
Learning Path:
1. IT security fundamentals
2. Industrial control systems
3. OT-specific training
4. Hands-on lab work
5. Specialized certifications
Resources:
- SANS ICS courses
- ISA training
- Vendor training
- ICS-CERT resources
OT cybersecurity is growing rapidly with strong demand for qualified professionals.
Common Questions
Should we air-gap our OT network?
Complete air-gap is increasingly impractical - business requires some connectivity for remote monitoring, updates, and data analysis. Instead, use strong segmentation, DMZ architecture, and controlled data transfer (unidirectional gateways where possible). Minimize connections and secure those that exist. Balance security with business needs.
How do we patch systems that cant be patched?
Many OT systems cant be easily patched due to availability requirements, vendor support, or compatibility. Use compensating controls: network segmentation, application whitelisting, enhanced monitoring, and access restrictions. Document the risk and compensating controls. Work with vendors on patch strategies during planned downtime.
What is the biggest OT security risk?
Currently, ransomware affecting IT systems that spreads to or impacts OT through interconnection. IT/OT convergence without proper segmentation creates risk. Other major risks: remote access vulnerabilities, supply chain compromise, and insider threats. Risk varies by industry and threat landscape.
How do we get started with OT security?
Start with asset inventory - you cant protect what you dont know about. Then network segmentation - separate IT and OT. Add monitoring for visibility. Develop incident response plans. Assess risks and prioritize improvements. Dont try to do everything at once. Progress is better than perfection.
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