Fundamentals of OT security training for OT operators

While advanced detection technologies and layered defenses are vital to secure OT, the most powerful first line of defense still remains the operators themselves. The moat between OT infrastructure and threat actors is often only as wide as the degree of OT security sensitivity and awareness maintained by OT teams and personnel. No where is it truer than in critical infrastructure.

Yet, OT operators are anything but traditional IT users. They work in environments where uptime is a non-negotiable factor, safety is paramount, and legacy systems run alongside mint fresh digital platforms. That is why OT security training must be native, contextual, tailored, immersive, and directly aligned with the realities of plant operations. Anything else will not deliver outcomes for your security team.

Today’s blog explores the fundamentals stuff that goes into designing an OT security training program for operators. It outlines measures you can initiate to create a security-aware workforce, integrate industry standards, deliver immersive learning, align training with real threats, and reinforce learning through day-to-day practice.

Before we begin, don’t forget to check out our last blog post on “OT infrastructure protection in power systems”.

Let’s begin today’s post.

The essentials of creating an OT security-aware workforce

Building a cyber-aware workforce is not merely about forcing OT operators to become cybersecurity experts having all the answers. Instead, it is about equipping them with the right level of awareness, actionable memory, instincts, and confidence to recognize OT security risks and to take appropriate action when a situation arises.

Start with the context and leave jargons behind

Many OT operators are engineers, technicians, or plant staff with years or even decades of operational expertise. Many operators have a personal bond or very high levels of relatability with OT systems and that should be treated as a strength.

They have no need to know how packet capture analysis or encryption algorithms work. Training should instead focus on what cybersecurity means in their specific environment:

· How can malware disrupt control systems?

· Why removable media policies exist?

· How unsafe use of remote access can lead to outages?

· Why air gapped systems do not automatically translate into the highest levels of OT security

· How can one spot an incident? What is an anomaly of interest?

· How to ensure vulnerabilities are fixed within timelines

Building a culture of responsibility, accountability and ownership

OT operators should feel ownership of security deep within, not that it is an “IT problem.” Training should reinforce that security lapses can lead to:

· Safety incidents and worker injuries.

· Regulatory fines or shutdowns.

· Loss of trust with customers and communities.

· Make the losses contextual. No need to bring Colonial Pipeline here. Instead focus on what an incident could cause in the site or the plant the person belongs to

· Demonstrate how lack of ownership could create security gaps

· What can unattended threat surfaces lead to?

· What can a misconfiguration at a network level lead to?

Focus on practical daily behaviors

Awareness is only meaningful if it translates into daily practice. The OT operator security training must highlight key security practices such as:

· Identifying unusual alarms or control anomalies.

· Verifying authenticity before applying patches or updates.

· Escalating suspicious activity without delay.

· Speaking up in time

· Ensuring the adoption of next steps beyond reporting

· Logging of anomalies and investigations

· RCA wherever possible

· Incident response steps 

The goal is to normalize secure behaviors (as a muscle memory) as part of routine plant operations, just as lockout/tagout or PPE are standard safety practices.

Incorporating standards and regulations: IEC 62443, NERC CIP, and NIS2

Any effective OT security training must base itself in recognized standards and compliance frameworks. Not only does this ensure regulatory alignment, but it also provides a structured roadmap for what operators should know. This also reduces the time to compliance and helps align internal practices.

IEC 62443

IEC 62443 is the global benchmark for industrial cybersecurity. For operator training, relevant elements include:

· Foundational Requirements (FRs): Access control, use control, data integrity, and response to events.

· Security Levels (SLs): Training operators on how their role supports the designated SL for their zone or conduit.

· Security Program Requirements: Familiarity with policies around patching, accounts, and incident reporting.

Operators don’t need to memorize the full standard, but they should understand how their actions contribute to compliance.

NERC CIP

For operators in the power sector, NERC CIP is non-negotiable. Key training focus areas include:

· CIP-004 (Personnel Training): Ensuring operators understand access restrictions and incident response requirements.

· CIP-005 (Electronic Security Perimeters): Awareness of what constitutes secure perimeters and how to handle connections.

· CIP-007 (System Security Management): Reinforcing patch management and malware protection practices.

By integrating CIP requirements into training modules, operators are prepared not just for security threats but also for regulatory audits.

NIS2 Directive

For operators in the EU, NIS2 is reshaping critical infrastructure security. Training should emphasize:

· Incident Reporting: Operators must know how and when to escalate cyber incidents within the mandated timelines.

· Risk Management Practices: Operators should see how their daily security hygiene contributes to organizational compliance.

· Sector-Specific Guidance: Tailoring training to the sector, whether energy, water, transportation, or manufacturing.

Bringing these standards together, OT security training becomes not just a compliance exercise but a practical shield against real-world risks.

Rendering a hands-on and immersive experience

One of the biggest challenges in OT security training is retention. Reading policies or watching slides has limited impact. Instead, immersive and hands-on training methods are proven to leave a stronger impression.

Simulated cyber-physical scenarios

· Attack simulations: Demonstrate how a phishing email targeting remote access credentials could halt a turbine.

· Incident response drills: Walk operators through a mock ransomware event on a SCADA workstation.

· Cross-functional exercises: Pair OT operators with IT and cybersecurity teams to simulate coordinated responses.

These scenarios build confidence, showing operators not only what could happen but also how they can react effectively.

Deploying digital twins and testbeds

Training in a live OT environment is risky, but digital twins or OT labs provide safe spaces for operators to practice. They can:

· Explore how configuration changes affect processes.

· Identify indicators of compromise in a controlled setting.

· Test escalation procedures without risking production downtime.

Best practices for retention

Operators often connect better with real-world incidents than abstract rules. Case studies and real life incidents as narrated by personnel themselves can illustrate how human errors, insider threats, or poor training contributed to attacks. Storytelling fosters retention, making lessons stick.

Aligning training with OT threat and risk assessments

No training program should exist in isolation. It must reflect the actual threat landscape and risk assessments of the plant or facility.

Map training to current threats

If assessments show phishing, USB-borne malware, or supply chain compromises as the top risks, then training modules should prioritize these threats. Operators should learn:

· What these risks look like in day-to-day tasks.

· What red flags to report.

· What steps to take in the critical first minutes.

Incorporate risk scenarios by zone

Using IEC 62443’s zoning and conduit model, training can be tailored:

· Enterprise Zone: Secure use of remote access.

· DMZ: Awareness of cross-zone data transfers.

· Control Zone: Recognizing anomalies in HMI/PLC behavior.

This helps operators link training directly to their work area, increasing relevance and engagement.

Make threat updates ongoing

The threat landscape evolves constantly. Quarterly micro-learning sessions, short updates, or “cyber safety moments” during shift handovers ensure training stays current with new adversary tactics or sector-specific alerts.

Post-learning tasks: Ensuring application of training

Training does not end when the classroom or simulation closes. Without reinforcement, lessons fade. Embedding post-learning tasks ensures knowledge translates into habitual secure behavior.

Security checklists for operators

Daily or weekly checklists can remind operators to:

· Verify secure logins.

· Monitor alarms for unusual activity.

· Follow strict procedures for removable media.

· Record and escalate anomalies.

· Avoid use of personal hotspots

Checklists are practical tools that anchor abstract lessons into concrete actions.

Peer-to-Peer Reinforcement

Encouraging operators to hold short “peer discussions” about security events or suspicious activity promotes collective accountability. This peer learning helps normalize security as part of culture.

Integration into Safety Drills

Since safety drills are already routine in OT environments, adding a cyber element, such as practicing manual shutdowns during a simulated ransomware attack, keeps security top of mind.

Managerial Reinforcement

Supervisors play a vital role in reinforcing training. Regular one-on-one discussions, short quizzes, or rewarding secure behavior strengthens knowledge retention and reduces complacency.

Continuous Feedback Loops

Operators should have easy ways to report challenges or uncertainties they face in applying training. This feedback loop ensures training programs evolve with the realities of the plant floor.

Cybersecurity in OT environments is not only about firewalls, air-gaps, and monitoring tools. It is about people on the front lines, operators who keep facilities running safely and reliably every day.

Effective OT security training is built on fundamentals:

· Creating awareness rooted in operational realities.

· Aligning with global standards and sector-specific regulations.

· Using immersive, hands-on methods for deeper learning.

· Tailoring training to actual threats and risks.

· Reinforcing knowledge through post-learning tasks.

When done right, OT security training transforms operators into vigilant guardians of critical infrastructure. It ensures that every action on the shop floor, from logging into a workstation to responding to an alarm, is carried out with a security-first mindset.

By embedding training into the DNA of OT operations, organizations can bridge the gap between human behavior and technical defenses, making their plants and sites safer, more resilient, and ready to withstand the evolving cyber threat landscape.

Connect with our OT security training experts to plan your next training