OT SCADA Penetration Testing: An Overview

OT and SCADA systems are the beating heart of critical infrastructure, controlling everything from the electric grid to water treatment facilities. But with increasing connectivity comes increasing risk. As these systems adopt standard IT technology, they become more exposed to cyber threats that could have devastating real-world effects. That's why penetration testing is so important.

Understanding OT/SCADA Systems

SCADA and OT systems are used to control and monitor industrial processes in a wide range of industries.

SCADA stands for Supervisory Control And Data Acquisition. It is a combination of hardware and software that allows you to automate industrial systems. They help monitor and control these systems and processes both locally and remotely by collecting and processing data from those systems.

According to Gartner, 'Operational technology (OT) is hardware and software that detects or causes a change, through the direct monitoring and/or control of industrial equipment, assets, processes and events.'

It's the hardware and software that detect and cause changes in the physical devices present in industrial control systems. It focuses on the industrial processes and operations and keeps them running 24/7.

Manufaturing, oil and gas, water and wastewater treatment, power grid management, are some of the many industries where OT and SCADA systems are used.

OT vs SCADA:

While OT and SCADA are closely related, they have different purposes. OT is an umbrella term used to describe the hardware and software that are used to manage industrial processes and operations. So SCADA is a part of OT.

Source: ABI Research

SCADA is the part of OT that only focuses on monitoring and controlling processes in real-time. The main function of SCADA is to collect data from the Central Control and Command Centre. 

Why Penetration Testing Matters for OT/SCADA

OT/SCADA Pen Testing Methodology

Penetration testing methodologies for OT/SCADA typically follow a similar process to IT systems. Testers start with information gathering to build a profile of the OT network and identify potential targets. This is done through open-source research, social engineering, and passive scanning. Any active scanning or exploitation is done carefully and incrementally to avoid system instability.

Passive Network Mapping

Passive network mapping involves observing traffic on the OT network to map connections between devices and systems. This can reveal network architecture, device types, communication protocols, and potential entry points. Passive mapping is a non-intrusive way to gather information before actively scanning the network.

Vulnerability Scanning

Vulnerability scanners are used to identify known security weaknesses in OT devices and software. Scans should be performed slowly while monitoring systems to avoid overloading aging components. Any critical vulnerabilities found should be addressed immediately.

Exploitation

The goal of exploitation is to gain access to systems and determine the level of access and control available. On OT networks, exploitation is done extremely carefully by security professionals with experience in ICS environments. Testers start with non-essential systems and slowly expand to critical infrastructure. The purpose is to demonstrate risk, not cause operational disruption.

Penetration testing of OT and SCADA systems requires specialized knowledge, training, and experience to balance security testing objectives with operational stability. When done properly, pen testing these critical systems provides valuable insight into real-world risks and helps organizations strengthen their security posture.

Best Practices for Safe and Effective OT/SCADA Penetration Testing

When it comes to penetration testing OT and SCADA systems, the  approach can differ from traditional IT systems. Why? These systems have unique security risks and vulnerabilities and need to be available at all times. Any disruptions to critical systems can lead to serious, costly, and far-reaching consequences.

That's why when it comes to these systems, safety and ethics are top priority. Some best practices to keep in mind:

Do no harm

The cardinal rule of any penetration test is “do no harm.” Make sure testing does not disrupt critical operations or damage equipment. Start with non-intrusive methods like port scans and vulnerability assessments before attempting to exploit any systems. Have contingency plans in place in case anything goes wrong.

Obtain proper authorization

Always get written permission from system owners before conducting testing. Clearly define the scope and objectives to ensure all parties understand what will be tested and how. Authorization should come from executives who can approve any potential disruptions.

Use an isolated test environment when possible

The ideal approach is to build an isolated replica of the target system and conduct testing there first. This allows you to verify the effectiveness and impact of any tools or techniques before using them on the live system. If building an exact replica isn’t feasible, at a minimum test in a sandboxed virtual environment.

Have OT/SCADA expertise on your team

Penetration testing OT and SCADA systems requires specialized knowledge beyond typical IT systems. Include experts with experience in the specific hardware, software, and protocols used in the environment. They should understand how systems and devices interact so testing does not inadvertently impact critical operations.

Conclusion

While these systems are complex and testing them does come with risks if not done properly, following industry best practices and working with experienced professionals can help ensure a successful engagement. Regular testing is key to gaining visibility into evolving threats, meeting compliance standards, and ultimately strengthening your organization's security posture. Now that you understand what's at stake and have a roadmap to get started, it's time to take action.