Why Modernization Holds the Key to Preventing OT Cyber Attacks

Summary

Cyberattacks are no longer a risk; they’re a reality. They cost industry millions in lost revenue, disrupt critical resource supply, damage reputations and impact society at large.
 
So, if it’s no longer a question of if, or whether a cyber attack succeeds, but how many times and in how many different ways it will succeed, can you say with confidence that your systems are resilient and ready in the face of this new reality? Or is it time to proactively and strategically modernize control systems to strengthen resilience and safeguard operations?
 
In 2023, 90% of the world’s largest energy companies experienced cybersecurity breaches. That year alone, there were more than 200 reported cyber incidents targeting the energy sector–more than half of them were directed specifically at Europe.
 
Last year, the North American Electric Reliability Corporation warned that US power grids are increasingly vulnerable to cyber attacks, while attacks on US utilities increased by 70% in the 12 months from 2023 to 2024.
 
Unsupported or outdated control systems, which sit at the heart of operations, significantly elevate breach risk. In addition to the outages, economic implications and social disruption, regulatory fines and enforced mitigation plans often follow these incidents, adding further costs, operational disruption and reputational scrutiny for businesses already under pressure.
 
Despite these clear and present risks, many organizations continue to underestimate this persistent threat. Fortunately, the solution is clear and easily implemented. To ensure your organization is best-placed to mitigate these threats, legacy OT systems must be urgently modernized.
 

OT cyber security solutions

Cyber security has traditionally been considered IT’s domain. However, OT equipment is increasingly targeted because unsupported control systems invite attacks.
 
While IT teams typically possess robust cybersecurity expertise, the story is different in OT. There, protecting control systems is often left to control engineers whose core areas of expertise understandably lie elsewhere. As a result, control systems that run on an outdated system are increasingly vulnerable. Therefore, if you’re not modernizing, it’s like leaving your house keys in your front door.
 
Undertaking an OT modernization program may sound financially daunting. However, you don’t have to take a costly rip-and-replace approach to your control systems. That risks downtime and exposes your systems to threats during the upgrade implementation. In this scenario, it would be like leaving your windows open while you put a new lock on your door.
 
Instead, a sustainable and cost-effective stepwise modernization program significantly reduces unplanned shutdowns and doesn’t leave your system open to attacks during the upgrade. A layer-by-layer program allows you to build customized solutions onto existing infrastructure, which is essential in OT where off-the-shelf solutions are rare because of the range of different threat levels, entry points and malicious actors at play.
 
ABB's head of Modernization, Volker Jung, has spent years advising customers around the world on how to modernize their operations. He often points to ENGIE’s South Australian Pelican Point power station as a standout example. Having originally developed and installed the plant’s control system in 2000, ABB was the natural choice when ENGIE sought to upgrade its cyber security infrastructure. Building on decades of collaboration, ABB implemented a phased modernization strategy of updating all software to the latest versions and deploying its advanced Cyber Security Workplace solution.
 
ENGIE took a proactive decision to safeguard operations, secure critical infrastructure and strengthen public trust. Like many proactive companies across the energy and infrastructure sectors, ENGIE recognized that you can’t successfully modernize if your control systems aren’t secure.
 

The cost of shutdowns

Unfortunately, many companies aren’t proactive and mistakenly assume they are supported and secure because they are isolated networks, i.e. ‘air-gapped’. However, while air-gapping was once considered a robust defense, the reality is that threat actors exploit numerous alternative entry points, from field devices to printers. And, every few months, a new OT entry point – a new threat – emerges that could result in a prolonged shutdown.
 
Downtime impacts your business. It can also impact society. Electricity network operator Ausgrid, which supplies energy to over 4 million Australians, as well as 105 hospitals, three major ports and 37% of the country’s financial services industry, reported that a shutdown of its infrastructure could have a worst-case economic impact of AUS$2.9bn (US$1.89bn) a day.
 
In industrial sectors like offshore and chemicals, unplanned downtime carries an even heavier burden. Costs and delays can escalate to up to three times higher than standard benchmarks due to harsh operating environments, the need for specialized materials and significant logistical hurdles. Outages in these sectors also pose a heightened risk to physical assets and stagnant, corrosive chemicals can rapidly degrade pipelines and equipment. These conditions often trigger cost overruns, driven by the unexpected need for equipment replacement and the long lead times associated with complex procurement and installation processes.
 
The financial costs don’t stop when you’re back up and running. Trojan sources can infect every single network device, which will all require replacing. By proactively modernizing, you are reducing the likelihood of a cyber attack resulting in substantial costs to your business.
 

Modernize to stay secure

It is essential to note that no one can guarantee that upgrading your control systems will prevent 100% of attacks from being successful. However, modernization enables you to significantly reduce risk across your systems while also optimizing sustainable performance, service delivery and overall resilience.
 
Organizations cannot afford to wait for a cyber attack to occur before taking action. Simply, the investment in modernization today pales in comparison to the potential costs of tomorrow's cyber attack. By implementing a strategic, stepwise modernization program that builds security layers onto existing infrastructure, you can significantly reduce your attack surface while maintaining operational continuity.
 
After all, every cyber attack succeeds–until it meets the right defense.