Safety, Security, and Seconds: Why Every Setting Counts in OT
Operational Technology Safety, Security and Seconds: Why Every Setting Counts
In industries such as oil & gas, petrochemicals, power generation and mining, even a few minutes of unplanned downtime can have serious consequences. It can result in substantial financial loss, harm to the environment and safety concerns. That’s why managing operational technology (OT) configurations is no longer a ‘nice to have’—it’s a must.
Modern industrial sites rely on many different systems, such as Distributed Control Systems (DCS), Programmable Logic Controllers (PLCs), Safety Instrumented Systems (SIS) and network devices. Keeping all of these in sync and running correctly requires a centralized, automated system. Here's why strong OT configuration management is essential:
1. Reduce Unplanned Downtime
Small, undocumented changes in settings, firmware or control logic (called configuration drift) can lead to system failures. An OT configuration management system helps avoid this by:
- Setting Baselines and Monitoring Constantly - The system creates a “known good” version of each device and keeps checking to make sure nothing changes unexpectedly.
- Faster Problem Solving - When something goes wrong, detailed records of changes make it easy to find out what happened.
- Quick Rollbacks - Engineers can restore systems to a safe, working state in seconds, not days.
According to The Reliability and Maintainability Center (RMC), the average cost of unplanned downtime across industries was estimated at-$260,000 USD per hour. Therefore, avoiding even one outage often pays for the system.
2. Improve Safety and Control
Safety systems and control loops are critical to plant operations. Configuration management supports them by:
- Requiring Approval for Changes - All changes must be reviewed and approved by safety, process and cybersecurity experts.
- Tracking Versions for Safety Checks – The system keeps a record of all changes, making it easier to meet safety standards like IEC 61511 and API 556.
- Ready-for-Audit Documentation - Detailed logs and electronic sign-offs help pass audits without last-minute scrambling.
Instead of reacting after something goes wrong, this approach makes safety proactive and verifiable by having the necessary data and checks in place to ensure a safe operating environment.
3. Boost Cybersecurity
Cyber threats are getting more advanced and companies need more than just basic security checks. Configuration management helps by:
- Working with Security Tools – Configuration management sends current system inventory information to vulnerability scanners to quickly spot unpatched or risky devices.
- Detecting Unauthorized Changes - If someone changes software, logic or network settings without approval, alerts are triggered.
- Keeping Detailed Change Records - This creates a solid trail for investigations and reports if a security incident happens.
Without these tools, attackers can stay hidden and cause real-world harm by making changes that could create a serious incident.
4. Support Digital Transformation
To take advantage of digital tools like digital twins, predictive maintenance and analytics, you need trusted data. Configuration management helps by:
- Providing Data - It supplies up-to-date, validated configuration information to systems that depend on reliable data.
- Breaking Down Team Silos – Everyone, from IT to engineering, can access the same configuration data.
- Testing Changes Before They Go Live - Engineers can review and validate changes offline before making them live.
Poor data can stop digital projects in their tracks. Good data moves them forward as all necessary stakeholders are working from the same verified and trusted, data set.
5. Meet Compliance and Standards
Regulations like IEC 62443, NERC CIP and API 1164 now require stricter controls on OT systems. Configuration management supports compliance by:
- Generating Audit Reports Automatically - All changes, approvals and baselines are tracked and reported automatically.
- Using Logs and Signatures - Changes are recorded with the previous and current state, protecting against legal or regulatory issues.
- Reducing Insurance and Legal Risks - Proving strong change control can lower insurance premiums and help avoid fines.
Manual tracking just can’t keep up with today’s compliance needs. Automation makes compliance management a much easier and accurate task by providing the data needed to comply with regulations and standards.
6. Save Time and Money
As the saying goes “work smarter not harder.” Good configuration management makes daily operations more efficient by:
- Automating Device Tracking - Devices are found, recorded and monitored automatically, which means no more messy spreadsheets.
- Planning and Testing Offline - Changes can be validated ahead of time and scheduled smartly, reducing maintenance time.
- Managing the Full Device Lifecycle - From setup to retirement, configurations are tracked to keep systems running longer and more reliably.
These time and cost savings add up, helping teams do more with fewer resources.
Why Hexagon’s Cyber Integrity and Automation Integrity Stands Out
Many companies offer configuration tools, but these solutions are built specifically for complex industrial environments. Here's what makes these solutions different:
- Handles Industrial Scale - Supports all major brands and types of control systems.
- Unified View Across All Devices - See everything in one place, so no more guesswork or tribal knowledge.
- Built-In Security & Compliance Tools – Has the ability to leverage templates aligned with IEC 62443, NIST and others to stay compliant.
- Easy Change Control and Audits - Built-in approvals and logs make audits stress-free.
- Supports Digital Twins - Configuration data powers accurate models and simulations.
- Open and Flexible - Works with your existing systems, on-premises, in the cloud or hybrid.
- Global Help, Local Support - Expert services and 24/7 support ensure fast results and smooth rollouts.
Shape
Act Now
Cyber threats are becoming more sophisticated and prevalent, posing significant risks to organizations across industries. As attackers continue to evolve their tactics, businesses must remain vigilant and proactive in safeguarding their systems and data.
At the same time, regulators and insurers are tightening their requirements, demanding higher standards of cybersecurity and operational resilience. Compliance is no longer optional—it’s a critical component of maintaining trust and avoiding penalties.
Digital transformation initiatives also rely heavily on trustworthy data to deliver meaningful results. Whether it’s optimizing operations, enabling predictive analytics or driving innovation, the success of these programs depends on the integrity and security of the data they use. Without robust cybersecurity measures in place, the reliability of digital programs can be compromised, hindering progress and exposing vulnerabilities.
Bottom Line
In high-risk industries where safety, uptime and compliance are critical, Hexagon’s Cyber Integrity and Automation Integrity gives you the visibility and control you need. Trust your configurations. Secure your future. Start today.