Why OT systems need red teaming

Cyber attackers no longer limit themselves to traditional IT network. They’re increasingly targeting Operational Technology (OT), the systems responsible for keeping factories operational, power grids stable, pipelines flowing, and refineries safe. In these environments, a breach isn’t just about data theft; it can result in operational downtime, safety hazards, environmental damage, and significant financial loss.

OT vs. IT: Why OT security requires a different approach

While most organizations routinely conduct penetration testing for their IT infrastructure, OT environments present a unique set of challenges. Many OT systems rely on legacy hardware and firmware that cannot be easily patched or updated. These systems are often fragile, and aggressive scanning or intrusive testing can crash controller’s mid-operation, potentially halting critical processes.

Moreover, the priorities in OT differ from IT, availability and safety take precedence over confidentiality. As a result, traditional vulnerability assessment and penetration testing (VAPT) methods are insufficient. OT environments demand red teaming approaches that are safe, precise, and focused on resilience rather than disruption.

Real-world examples of OT attacks

OT attacks are no longer theoretical. They’ve been operationalized by threat actors across industries. 

• In 2015, attackers infiltrated the Ukraine power grid, pivoting from IT systems to OT and remotely opening breakers, causing widespread outages. 
• The CRASHOVERRIDE/Industroyer malware in 2016 was specifically designed to manipulate grid protocols and automate disruptive actions.
• In 2017, TRITON/TRISIS targeted Safety Instrumented Systems (SIS), trying to disable critical safety layers.
• The Colonial Pipeline ransomware attack in 2021 forced a proactive OT shutdown, disrupting fuel supply across the U.S., while the Oldsmar Water Treatment incident highlighted vulnerabilities in remote access controls when unauthorized changes were made to chemical dosing levels.

These examples underscore that OT attacks are not hypothetical, they’ve already impacted energy, oil and gas, manufacturing, and utility sectors worldwide.

Testing OT systems without disrupting operations

A common concern among OT operators is how to conduct security testing without risking downtime. At CPX, our methodology is designed to prioritize safety and always maintain operational continuity.

We begin by using replica or digital twin environments to mirror critical OT assets in a secure lab setting. This allows us to simulate real-world adversary tactics such as lateral movement, pivoting, and PLC exploitation without interacting with live production systems. These simulations provide deep insights into vulnerabilities while ensuring zero impact on actual operations.

In live environments, we shift to non-intrusive validation techniques, which include:

• Passive monitoring of network traffic and system behavior
• Configuration reviews to identify misconfigurations and outdated settings.
• Controlled demonstrations conducted under operator supervision to validate potential attack paths safely.

This dual approach ensures that testing is both effective and safe, delivering valuable insights without compromising the integrity or availability of critical OT systems.

Delivering actionable outcomes through red teaming

Our red team engagements are designed to produce tangible results. We provide detailed attack-path maps that trace potential routes from IT to OT systems. These are accompanied by remediation playbooks that offer both quick wins and long-term strategies.

Additionally, we deliver board-ready reports that translate technical risks into business impacts, helping leadership understand the value and urgency of OT security.

The leadership perspective: Why OT security is critical

For executives and board members, the stakes are high. Every avoided outage can save millions on operational costs. Regulatory compliance is also a driving factor, with standards such as IEC 62443, NERC, and UAE’s Information Assurance (IA) framework requiring validation of OT security. Demonstrating that OT systems have been tested against real-world threats builds confidence and assurance at the highest levels of the organization.

Business impact: Downtime isn’t an option

Unplanned downtime in OT environments can be extraordinarily costly, often hundreds of thousands of dollars per hour. In sectors like oil and gas or power generation, a single incident can escalate into multi-million-dollar losses, regulatory penalties, and long-term reputational damage. The financial and operational risks make proactive OT security not just a technical necessity, but a business imperative.

Conclusion: Protecting people, operations, and trust

Whether you operate a refinery, power plant, pipeline, or manufacturing facility, OT red teaming offers a critical lens into your environment seeing it as an attacker would, before they get the chance. It’s not about breaking systems; it’s about protecting operations, people, and the trust that keeps your business running.

Connect with CPX to explore our red teaming services for OT environments.