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The Role of IT/OT convergence in enhancing cyber security in Power Utilities 
The Role of IT/OT convergence in enhancing cyber security in Power Utilities 

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In the context of utilities, cyber posture refers to an organization's overall cybersecurity readiness and resilience against cyber threats. It encompasses the people, processes, and technologies safeguarding systems, networks, and data.  

For those unfamiliar with IT and OT, here is a simplified explanation:  

  • IT (Information Technology): Comprises hardware, software, and data networks that support business functions such as finance, ERP, HR applications, and business growth-related operations.  
  • OT (Operational Technology): Includes industrial control systems, data acquisition systems (PLC/SCADA), and industrial networks that utilize computing, networking, and storage technologies to manage physical devices and processes.  

Evolution of IT and OT in Substations  

Control Relay Panels (CRP) and Substation Automation Systems (SAS) typically account for 5%-7% of the total Substation project cost in substation projects. The IT component of CRP and SAS comprises 35%-40% of the hardware and software.  

Around the year 2010, substation tenders followed a long cycle—from publication to award and execution—which often spanned 2-3 years. Since substation automation equipment was installed in the final stages of the project, laptops of configurations mentioned in tenders were frequently used to get obsolete in markets by the time they were procured and supplied. We advised customers to specify minimum required configurations rather than fixed hardware models to address this.  

OT Environment and Priorities  

OT environments have traditionally been designed for longevity, often with a lifespan of 25 years or more. One instance I remember when I visited the Roorkee substation of PTCUL* in 2005, I observed an electromechanical busbar protection relay that had been in operation for over 50 years. The substation Engineer proudly mentioned that its maintenance costs were negligible.  

Unlike IT, which frequently upgrades software and hardware, OT systems are vendor-dependent and upgrade cycles are much longer. Historically, cybersecurity was not a priority in OT environments—safety and operational efficiency took precedence. Even though OEMs released new firmware versions, OT engineers often hesitated to implement updates unless necessary.  

IT Environment and Priorities  

IT environments focus on enterprise-level concerns such as protecting intellectual property, information systems, and customer data. Over the years, IT has undergone rapid advancements, with processing speeds and storage capacities increasing exponentially. Cybersecurity has been a core focus of IT for years, with frequent updates and security measures being implemented proactively.  

The Need for IT/OT Convergence  

Some argue that OT should function independently, but inefficiencies in standalone OT systems present significant challenges. Utilities lack real-time fault diagnostics, timestamped event logs, and system-wide visibility without IT integration. The benefits of IT in OT are substantial—modern relays provide fault records with millisecond accuracy, and monitoring systems generate valuable operational data. Digital transformation is inevitable, and while it introduces risks, managing those risks is the only viable path forward.  

Challenges in Utility OT Security  

  1. Legacy Products: Many OT products were designed decades ago with proprietary communication protocols. While Ethernet-based IEC 61850 protocol has standardized communication, legacy systems with outdated Windows-based operating systems still pose security risks.  
  2. Remote Configuration Risks: While remote access enhances vendor support, it also increases exposure to cyber threats, primarily through VPN connections.  
  3. Patch Management: Managing updates across multiple vendor devices is cumbersome, leading to outdated firmware remaining in service until a security incident occurs.  
  4. Shortage of Skilled OT Cybersecurity Professionals: There is a growing demand for experts who understand both OT networks and cybersecurity.  
  5. Limited Visibility: Many utilities lack a comprehensive view of all endpoints, creating blind spots in cybersecurity defences.  

IT/OT Convergence Challenges  

  1. Cultural and Operational Differences: IT and OT teams have distinct priorities and mindsets, making collaboration difficult.  
  2. Increased Cyber Threats: Converging IT and OT expands the attack surface, making systems more vulnerable to malware, ransomware, and other threats.  
  3. Visibility Constraints: Limited monitoring tools for OT networks can reduce security effectiveness.  
  4. Risk of Unintended Operations: Cyber incidents in OT environments can result in physical harm, equipment damage, and operational disruptions.  
  5. Regulation: CEA(Central Electricity Authority) India still recommends that maintaining IT and OT networks should be isolated and that convergence is not recommended. In my view, this is justified considering the unpredictability of utilities to manage IT/OT convergence topics on the National Level in India.   

Benefits of IT/OT Convergence  

  1. Real-Time Data Insights: Improved access to sensor, machine, switch, and device data enables better network management.  
  2. Holistic Network Security: A unified approach enhances overall cybersecurity and operational resilience.  
  3. Cyber-Physical Security Collaboration: Joint efforts between IT and OT teams create a more comprehensive security strategy.  
  4. Trust and Cooperation: Strengthening collaboration between IT and OT teams reduces cyber risks at the organizational level.  

Conclusion  

IT/OT convergence is essential for enhancing utilities' cyber posture. While challenges exist, the benefits of increased visibility, improved security, and operational efficiency outweigh the risks.      

*PTCUL – Power Transmission Corporation of Uttarakhand Limited  

Author

Saurabh Srivastava Head-Utilities – Digital Transformation Office
Cisco

Saurabh Srivastava

Head-Utilities – Digital Transformation Office
Cisco

 


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