Why Are Cyberattacks on OT Systems More Dangerous Than IT Breaches?

When people think of cyberattacks, they often picture stolen data, financial fraud, or personal privacy violations. While these threats are serious, they pale in comparison to what’s at stake in Operational Technology (OT) environments—power grids, water treatment plants, oil refineries, and industrial control systems. Unlike IT breaches that primarily cause data loss, OT cyberattacks can lead to real-world disasters, including physical destruction, environmental damage, and even loss of life.

The Unique Risks of OT Cyberattacks

OT systems control the physical processes that keep industries running. Their main priority is uptime and operational continuity, not cybersecurity. As a result, many OT networks remain vulnerable due to legacy systems, lack of security updates, and minimal authentication controls. Here’s why cyberattacks on OT systems are particularly dangerous.

Physical Consequences from Disruptions to Disasters

Unlike IT breaches that primarily result in data theft, OT cyberattacks can have severe real-world consequences. When industrial control systems are compromised, the effects extend beyond financial losses—impacting public safety, infrastructure stability, and even human lives.

• In 2021, a hacker attempted to increase sodium hydroxide levels in a Florida water treatment facility, which could have poisoned thousands.
• In 2021, the Colonial Pipeline ransomware attack led to fuel shortages across the United States after operators shut down the pipeline to contain the breach.
• In 2017, the NotPetya ransomware attack disrupted shipping giant Maersk, pharmaceutical company Merck, and food manufacturer Mondelez, causing billions in damages and widespread supply chain disruptions.
• In 2015 and 2016, Ukraine’s power grid was attacked, causing widespread blackouts affecting hundreds of thousands of people.

Unlike IT breaches, where companies can recover lost data, OT cyberattacks often result in irreversible physical damage, causing millions in economic losses and endangering lives.

Legacy Systems and Security Weaknesses from the Past

Many industrial systems in use today were designed decades ago, long before cybersecurity became a critical concern. As a result, these legacy systems lack fundamental security protections, making them prime targets for modern cyber threats.

• Many industrial control systems (ICS) were designed with no built-in security features.
• Outdated PLCs, RTUs, and SCADA systems often lack encryption and authentication, making them easy targets for attackers.
• Unlike IT systems that are frequently updated, many OT devices run on "set and forget" configurations, leaving them vulnerable for years.

Lack of Visibility and Incident Response

One of the biggest challenges in OT security is detecting and responding to cyber threats in real time. Many industrial environments lack the necessary visibility into network activity, allowing attackers to operate undetected.

• Limited monitoring tools mean that intrusions can go undetected for weeks or even months.
• Many industrial sites don’t have dedicated cybersecurity teams, relying instead on operational engineers who may not have deep security expertise.
• Unlike IT environments, patching OT systems is complex—downtime for security updates could mean halting entire production lines.

Remote Access Risks and the Backdoor to OT Systems

As industrial environments embrace digital transformation, remote access has become a necessity. However, the widespread use of VPNs and weak authentication methods has introduced new attack vectors that hackers actively exploit.

• VPNs and remote access tools introduced for convenience have become major attack vectors.
• Many OT devices still use default passwords, making them easy to compromise.
• Recent ransomware attacks have exploited weak authentication controls, granting hackers access to industrial networks.

How Can OT Operators Strengthen Their Security?

As cyber threats targeting OT systems continue to rise, organisations must take proactive steps to enhance their defences. A multi-layered security approach can help mitigate risks and ensure operational continuity.

First, strict authentication measures should be implemented to prevent unauthorised access. Static credentials, such as default passwords and shared logins, remain a major vulnerability in OT environments, making dynamic and role-based authentication crucial.

Second, network segmentation is essential to limit an attacker's ability to move laterally between IT and OT environments. By isolating critical systems and enforcing access controls, organisations can minimise the impact of potential intrusions.

Third, monitoring and updating legacy systems is critical, even though patching can be challenging in OT environments. Regular security assessments and phased modernisation strategies can help reduce vulnerabilities without disrupting operations.

Finally, staff training and awareness play a key role in OT security. Many cyber incidents stem from human error, so educating employees on best practices—such as recognising phishing attempts and handling remote access securely—can significantly reduce risks.

Where Does swIDch Fit In?

swIDch’s PLC OTAC secures access to industrial control systems by eliminating static credentials, ensuring only authorised personnel can interact with critical OT networks. Additionally, OTAC Trusted Access Gateway (TAG) enhances security for remote access, replacing vulnerable VPN and password-based authentication methods with dynamic, single-use authentication codes—helping OT organisations prevent unauthorised access without disrupting operations.