Why OT security is critical for energy and industrial operations

Energy, utilities and industrial organisations face a unique cybersecurity challenge: how to secure decades-old industrial systems in increasingly connected environments? From remote pipeline sensors to offshore drilling rigs, OT environments were never designed with cyber threats in mind. But today, attackers know exactly where to look, and how to cause real-world impact.

Unlike IT systems, a breach in OT can result in physical damage, environmental harm, and even risk to human life. Whether the threat is ransomware, a misconfigured PLC, or a nation-state actor probing for weaknesses, the potential fallout is serious.

That's why OT security can’t be treated as an afterthought. It requires purpose-built tools and practices that go beyond traditional IT defences, delivering visibility, control, and early warning in environments that were never meant to be online.

Here are five real-world OT risk scenarios, and how the right security approach helps mitigate them.

1. Ransomware attack on a remote pipeline control system

Remote pipeline facilities often run with minimal on-site staff and outdated systems. These environments typically lack visibility and strong security controls, making them prime targets for ransomware groups. Attackers use phishing, exposed remote services, or compromised credentials to gain access, then encrypt files or disrupt communications to force payment.

How OT security helps:

• Asset discovery & inventory: Identifies every connected OT device, HMI panels, SCADA servers, PLCs, including legacy assets that may be forgotten or undocumented.
• Vulnerability management: Detects unpatched systems running old versions of industrial software, like SCADA platforms with known exploits.
• Network segmentation & access control: Prevents lateral movement by isolating infected zones or outdated endpoints.
• Anomaly detection: Flags unusual patterns like unauthorised command sequences or abnormal traffic between devices.
• Incident response tooling: Enables rapid containment, such as remotely disconnecting compromised nodes or segmenting infected networks.

Outcome:

Operational continuity is maintained while ransomware is isolated. Downtime is reduced, and recovery is faster and more controlled.

2. Third-party contractor introduces malware

Energy operations regularly involve external contractors, maintenance teams, system integrators, and equipment vendors. But third-party laptops or USB drives can become vectors for malware, especially if they’ve previously connected to less secure environments. Without strict controls, these devices can quickly become an entry point into the OT network.

How OT security helps:

• Zero Trust access controls: Every user and device must authenticate and be explicitly authorised, regardless of whether they’re ‘internal’ or external.
• Network Access Control (NAC): Validates endpoint health before allowing any connection to the OT network. Infected or non-compliant devices can be automatically quarantined.
• Real-time monitoring: Alerts triggered by unexpected or abnormal activity, such as a contractor device trying to scan the network or communicate with a critical PLC (Programmable Logic Controller).
• OT network segmentation: Third-party access is confined to designated network segments, separated from critical control systems.
• Audit logging: Every contractor interaction with OT assets is logged for accountability and post-incident review.

Outcome:

Malicious or compromised third-party access is contained early. You maintain compliance with supply chain security policies and avoid business disruption due to poor contractor hygiene.

3. Misconfigured PLC leads to safety system failure

PLC misconfigurations are one of the most common and dangerous causes of industrial downtime. An engineer uploads a new logic file or firmware patch to a live device without proper testing, unintentionally disabling safety mechanisms or interrupting process control. If left unnoticed, these errors can lead to equipment damage or safety incidents.

How OT security helps:

• Configuration management: Tracks all changes to PLC logic, firmware versions, and parameter sets, providing full visibility over who changed what, and when.
• Baseline enforcement: Compares current configurations to a known-good version and highlights any deviation in real time.
• Alerts for unauthorised changes: Notifies operations teams if a device is altered outside of approved maintenance windows.
• Digital twin or simulation testing: Allows engineers to test control logic in a virtual model before deploying it to live systems.

Outcome:

Misconfigurations are caught before they result in system failure. Safety-critical operations continue without disruption, and human error is minimised.

4. Nation-state APT targets offshore drilling platform

Offshore platforms are high-value, isolated targets with long operational lifespans. Their mix of legacy systems, proprietary protocols, and limited bandwidth makes them attractive to advanced persistent threat (APT) groups looking for strategic footholds. Once inside, an attacker can lie low for months, gathering intelligence or staging sabotage.

How OT security helps:

• Threat intelligence integration: Matches live network activity against indicators of compromise and tactics used by known APT groups.
• Behavioural analytics: Identifies long-term, low-noise anomalies that could indicate advanced threat presence.
• Deep packet inspection (DPI): Analyses traffic across OT protocols (Modbus, DNP3, etc.) to detect malicious commands or unauthorised control changes.
• Forensics & threat hunting tools: Helps incident responders understand attack paths and gather evidence during and after a breach.
• Strong IT/OT segmentation: Ensures that if IT systems are compromised, the attacker can’t pivot into the OT environment.

Outcome:

Advanced threats are detected and contained before sabotage or espionage can succeed. Long-term risk to offshore production is minimised.

5. Insider threat exploits lack of OT visibility

Not all threats come from the outside. In OT, a well-placed insider or even a careless employee can cause significant damage. Without detailed logs, behavioural monitoring, or proper access control, it’s difficult to know what users are doing or if they’re following protocol.

How OT security helps:

• User Behaviour Analytics (UBA): Monitors how users interact with systems over time, building baselines and flagging deviations.
• Role-Based Access Control (RBAC): Limits users to only the systems and actions they need no more, no less.
• Privileged Access Management (PAM): Logs and monitors sessions where users have elevated access, like admin rights on PLCs.
• Change management alerts: Detects configuration changes or maintenance tasks that fall outside of approved workflows.
• Audit trails: Maintain detailed records of user interactions for accountability and investigation.

Outcome:

Insider threats are identified quickly, whether intentional or accidental. You gain the ability to prevent and investigate actions that traditional perimeter defences would miss.

Securing industrial operations

IT and OT environments face different risks and need different protections. Traditional IT security tools aren’t built for the complexity, constraints, and protocols of industrial networks. That’s why OT security requires its own approach, with visibility into assets, strict access control, real-time monitoring, and the ability to respond fast when something goes wrong. With the right capabilities in place, energy and utilities operators can secure critical infrastructure without slowing down operations.

Need help securing your OT environment? Our experts are here to support you. Together with our OT security partners, we help you assess, design, and implement a strategy that fits your operations.