Top 5 Cybersecurity Pitfalls in Operational Technology (OT)

Methods to Avoid Costly Breaches and Improve Compliance in 2025

As the cybersecurity landscape for operational technology continues to evolve, many organizations using it still struggle with fundamental security practices. Recent incidents, including state-sponsored attacks from Russia and China targeting critical infrastructure, have highlighted the urgent need for robust cybersecurity measures across the energy industry. In this article, we’ll dive into five critical cybersecurity pitfalls related to operational technology as well as some actionable solutions that can strengthen your organizational resilience and security posture. 

1. Inadequate Identity and Access Management

The Problem

One of the most prevalent cybersecurity issues related to operational technology is poor identity and access management practices. Many organizations still assign a single, shared password to all operations technicians, lack proper password policies, and fail to implement multi-factor authentication (MFA). As the energy sector undergoes rapid digital transformation, this security gap will become extremely critical.

The Solution

A robust identity and access management (IAM) lifecycle framework starts with implementing stringent password policies that mandate regular updates, special characters, and minimum length requirements to prevent credential compromise. Multi-factor authentication should be deployed across all system access points, adding an essential additional security layer beyond basic passwords. Companies that use operational technology should move away from shared accounts by establishing role-based access control with individual user credentials, allowing for precise tracking of system activities and accountability. Equally important is the development of thorough onboarding and offboarding procedures for technicians, ensuring new staff receive proper security training and access privileges, while guaranteeing that departing employees have all access immediately revoked to prevent potential security gaps with individual user credentials.

2. Insufficient Asset Inventory Management

The Problem

Most industrial operations teams lack comprehensive digital asset inventories. While they may track expensive rotating equipment, they often treat complex SCADA (Supervisory Control and Data Acquisition) systems as a single asset, overlooking thousands of instruments, Programmable Logic Controllers (PLCs), and miles of cable that require individual tracking and security management.

The Solution

Organizations should implement comprehensive digital asset management systems that provide real-time visibility across their infrastructure. This begins with creating and maintaining detailed inventories of all connected devices and systems, from field sensors to control room workstations. Regular audits and updates of these asset lists are crucial, as outdated inventories can create dangerous blind spots in security coverage. Stakeholders should also maintain precise tracking of firmware versions and patch levels across all digital assets, enabling prompt identification of vulnerable systems requiring updates. Additionally, thorough documentation of system interconnections and dependencies is essential, as understanding these relationships is critical for assessing potential security impacts and maintaining operational continuity during system changes or security incidents.

3. Unsecured Remote Access

The Problem

Third-party vendor access remains a significant vulnerability and can lead to serious breaches. Many organizations allow vendors to access SCADA systems remotely without proper security controls, breaking air-gap protection claims.

The Solution

A robust defense strategy integrates VPN technology for all remote connections, establishing encrypted tunnels that deliver both secure data transmission and verified identity authentication. Organizations leading in this space implement comprehensive session monitoring and logging capabilities, empowering security teams to maintain continuous visibility, while generating detailed audit trails for incident response. Strategic time-windowing of maintenance access naturally constrains the attack surface, while systematic reviews of access permissions ensure vendor privileges remain precisely aligned with operational requirements. This defense-in-depth approach to remote access management has proven particularly effective in protecting critical infrastructure from unauthorized penetration through vendor connections—a critical consideration where a single compromise could trigger significant operational impacts.

4. Poor Legacy System Management

The Problem

Organizations struggle with managing unsupported legacy systems, which can lead to desperate measures. Consider a scenario where a field technician purchases a Remote Terminal Unit (RTU) from an online marketplace like eBay simply because the original part is no longer manufactured. This seemingly simple procurement decision introduces significant supply chain risks, as there's no way to verify the device's integrity or history, potentially compromising the entire infrastructural security posture.

The Solution

Legacy system management presents one of the most complex challenges in operational technology, where aging infrastructure often intersects with modern security requirements. A strategic approach to legacy system protection integrates robust compensating controls, carefully designed to mitigate vulnerabilities in systems where traditional patching proves infeasible. Detailed documentation of these compensating controls provides essential visibility and consistency across security operations while establishing clear governance over the exceptions process. Forward-looking organizations cultivate trusted procurement channels for replacement components, addressing the critical challenge of supply chain integrity for legacy hardware. This comprehensive strategy culminates in a systematic modernization roadmap, balancing immediate security needs against long-term infrastructure evolution.

5. Inadequate Network Segmentation

The Problem

While many organizations implement basic network segmentation, they often fail to maintain and verify these security boundaries over time. As systems evolve and new devices are added, segmentation can break down, creating potential security vulnerabilities.

The Solution

A sophisticated segmentation architecture builds upon clearly defined security levels, establishing strict boundaries between operational zones to minimize the potential spread of threats while preserving operational flexibility. Regular boundary testing validates these protective measures, while stringent protocols for devices maintain the integrity of each network segment over time. Comprehensive documentation of authorized communication paths enables security teams to detect anomalous traffic patterns, strengthening incident response capabilities. Annual architectural security assessments provide the strategic insight needed to evolve this segmentation framework, ensuring it keeps pace with both emerging threats and operational requirements.

Looking Ahead to 2025

As regulatory oversight increases and state-sponsored threats continue to evolve, the energy sector stands at a critical inflection point in its security journey. Critical infrastructure teams must move beyond the "air-gapped" mentality— especially as we progress through 2025, where the convergence of geopolitical tensions and sophisticated cyber threats makes robust security practices non-negotiable. While the threats from domestic and state-sponsored actors continue to mount, the focus must remain on mastering the fundamentals before pursuing advanced security measures. Organizations that delay implementing these core security practices risk not just operational disruption, but potentially catastrophic consequences. Our specialists stand ready to help assess your posture and develop a roadmap for strengthening your security framework.

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