Industrial Cyber Security
Cyber Security for PLC, SCADA and Industrial Automation Systems
Modern industrial automation systems are increasingly connected. PLCs communicate with SCADA platforms, production data is shared across networks and remote access allows engineering teams to support equipment without always being physically present on site.
Greater connectivity provides significant operational benefits, but it also means industrial control systems must be designed and maintained with cyber security in mind.
Industrial cyber security focuses on protecting Operational Technology (OT), including PLCs, SCADA systems, HMIs, industrial networks and connected production equipment, while maintaining the availability and reliability required by manufacturing operations.
At Stratos, we consider cyber security as part of the wider industrial automation environment, helping organisations identify control system vulnerabilities and implement practical measures to reduce operational risk.
What Is Industrial Cyber Security?
Industrial cyber security is the protection of Operational Technology and Industrial Control Systems from unauthorised access, disruption and cyber threats.
Industrial environments can include:
PLCs.
SCADA systems.
HMIs.
Industrial computers.
Engineering workstations.
Industrial networks.
Variable Speed Drives.
Remote access systems.
Historian systems.
Connected production equipment.
Unlike traditional IT environments, industrial cyber security must consider not only information security but also production availability, equipment reliability and operational safety.
Cyber Security for SCADA Systems
SCADA systems often provide visibility and supervisory control across significant areas of an industrial facility.
Protecting the SCADA environment may involve considering:
User accounts.
Access permissions.
Server configuration.
Workstation security.
Network architecture.
Remote connections.
Software versions.
System backups.
Communication interfaces.
Third-party access.
Security measures should be appropriate to the operational importance of the SCADA system and the potential consequences of disruption.
PLC Security
PLCs directly control industrial equipment and processes, making unauthorised changes to control logic or configuration particularly important to prevent.
PLC security considerations may include:
Programming access.
User permissions.
Network connectivity.
Engineering workstation access.
Controller configuration.
Firmware management.
Software backups.
Change management.
Physical access.
Where supported by the platform, appropriate security functionality should be configured without unnecessarily affecting production or maintenance activities.
Industrial Network Segmentation
Industrial automation networks have historically been designed primarily around communication and availability.
As industrial systems become increasingly connected to wider business infrastructure, separating systems according to their operational requirements becomes more important.
Network segmentation can help establish boundaries between:
Corporate IT networks.
Industrial OT networks.
SCADA systems.
PLC networks.
Engineering workstations.
Remote access systems.
Individual production areas.
Third-party equipment.
A structured network architecture can reduce unnecessary communication paths and limit exposure between different parts of the organisation.
Secure Remote Access
Remote access can provide significant benefits for engineering support and fault diagnosis, but unrestricted access to industrial automation systems can introduce unnecessary risk.
Secure remote access should consider:
User authentication.
Access permissions.
Approved users.
Connection methods.
Session control.
Network separation.
Access logging.
Time-limited access.
Monitoring requirements.
Access should be provided according to operational requirements rather than simply making the entire automation network remotely accessible.
User Access and Permissions
Not everyone working within an industrial facility requires the same level of access to automation systems.
Different permissions may be appropriate for:
Operators.
Maintenance technicians.
Automation engineers.
System administrators.
Production managers.
External contractors.
Equipment suppliers.
Role-based access helps reduce the risk of unauthorised or accidental changes while still allowing personnel to perform their required tasks.
Legacy PLC and SCADA Security
Older automation equipment can present particular cyber security challenges.
Legacy systems may rely on:
Unsupported operating systems.
Obsolete SCADA software.
Older PLC firmware.
Legacy communication protocols.
Unsupported engineering software.
Ageing network equipment.
Limited security functionality.
Replacing every legacy system immediately may not be practical.
A risk-based approach can identify the most significant vulnerabilities and determine whether systems should be isolated, protected, upgraded or incorporated into a longer-term modernisation strategy.
Industrial System Backups and Recovery
Reliable backups are an important part of industrial cyber resilience.
Backups may include:
PLC programs.
HMI applications.
SCADA projects.
Drive parameters.
Server configurations.
Historian databases.
Engineering documentation.
Network configurations.
Backups should be organised, version controlled where appropriate and stored so they remain available if the live system is compromised or equipment fails.
A backup is only useful if the organisation knows what it contains and can restore it when required.
Software, Firmware and Obsolescence Management
Unsupported software and hardware can increase the difficulty of maintaining a secure industrial environment.
Industrial cyber security planning should therefore consider:
SCADA software versions.
Operating system support.
PLC firmware.
HMI software.
Engineering applications.
Server infrastructure.
Network equipment.
Manufacturer lifecycle status.
Understanding which systems are approaching obsolescence allows upgrades to be planned before unsupported technology becomes a significant operational risk.
IT and OT Integration
Industrial environments increasingly require information to move between Operational Technology and traditional IT systems.
This may support:
Production reporting.
Industrial dashboards.
Historian systems.
Remote monitoring.
Business intelligence.
Maintenance systems.
Production planning.
IT and OT integration should be carefully designed so that the requirement to share information does not create unnecessary access to critical automation equipment.
Clear responsibility between IT and engineering teams is also important when managing connected industrial environments.
Industrial Cyber Security Assessments and System Hardening
Improving industrial cyber security begins with understanding the existing automation environment.
An assessment may consider:
PLC platforms.
SCADA architecture.
Industrial networks.
Remote access.
User permissions.
Software versions.
Legacy equipment.
Backup arrangements.
External connections.
Existing documentation.
Once risks have been identified, practical system-hardening measures can be prioritised according to operational importance.
These may include removing unnecessary access, improving network architecture, strengthening authentication, reviewing permissions, updating supported systems and improving backup arrangements.
Why Choose Stratos for Industrial Cyber Security?
Industrial cyber security requires an understanding of how automation systems actually operate.
Changes that may be straightforward within a conventional IT environment can have very different consequences when applied to PLCs, SCADA systems and production networks where availability and reliability are critical.
Stratos combines PLC programming, SCADA engineering, industrial networking and automation expertise to help organisations consider cyber security within the context of their operational environment.
Our focus is on practical engineering measures that reduce unnecessary risk while maintaining the availability and functionality required by production.
Strengthen the Security of Your Industrial Automation
Greater connectivity should not create unnecessary risk to production. Stratos helps organisations assess and improve the security of PLC, SCADA and industrial automation environments through practical engineering measures designed around operational requirements. Speak to our engineers about strengthening the resilience of your industrial control systems.
Frequently Asked Questions
What is industrial cyber security?
Industrial cyber security focuses on protecting Operational Technology, including PLCs, SCADA systems, HMIs, industrial networks and connected production equipment, from unauthorised access and disruption.
How is industrial cyber security different from IT cyber security?
Traditional IT cyber security primarily focuses on protecting information and business systems. Industrial cyber security must additionally consider the availability, reliability and safe operation of physical production equipment and processes.
Can older PLC systems be secured?
Older PLCs may have limited built-in security functionality, but risks can potentially be reduced through measures such as network segmentation, controlled access, improved backups and planned modernisation.
Is remote access to a PLC or SCADA system safe?
Remote access can be implemented securely when appropriate authentication, permissions, network architecture and access controls are used. Unrestricted or poorly configured remote access can introduce unnecessary risk.
Should PLC and SCADA systems be connected to the corporate IT network?
Industrial and corporate systems may need to exchange information, but connectivity should be carefully designed. Appropriate segmentation and controlled communication can help prevent unnecessary access to critical automation systems.