When backups fail in an operational technology (OT) environment, the fallout can be severe: extended downtime, compliance issues, or even safety incidents. And yet, backup strategy remains one of the most overlooked areas in OT security.
This blog breaks down common backup failures, what makes OT recovery unique, and how to build a backup strategy that actually works when it counts.
Common OT Backup Mistakes
Backup failures in OT environments can cause more than data loss. They halt production, damage equipment, and leave you scrambling during a cyberattack.
1. Not Testing Restores
If you’ve never tested a restore, you don’t know your backup works. Incomplete images, corrupt files, or missed systems are common—and you won’t find out until you’re in crisis mode.
2. Unclear RTO and RPO
Most teams don’t define Recovery Time Objective (RTO) or Recovery Point Objective (RPO) based on operational impact. If a critical HMI goes down, how fast do you need it back? How much data can you afford to lose? RTOs depend on system criticality and redundancy. RPOs may be less strict for real-time systems, but you still need multiple recent restore points to be safe.
3. Relying on Outdated Agents
Legacy OT systems often can’t run modern backup agents, making traditional tools ineffective. Hypervisor snapshots help—if the environment is virtualized. Many aren’t.
4. Storing Backups in Exposed Locations
If backups live on the same domain or network as your OT systems, they’re exposed to the same ransomware or credential theft. Without isolation, your backup is a liability.
Best Practices for Backups in OT Environments
1. Define RTO/RPO by System Impact
Use system criticality to set RTOs. Need rapid recovery? Use hypervisors or pre-staged images. RPOs are often less about data volume and more about maintaining operational state—keep enough restore points to match your test cadence.
2. Air-gap, Encrypt, and Lock Backups
Backups must be offline (air-gapped), unchangeable (immutable), and encrypted. That’s how you defend against ransomware and meet compliance standards like BCSI.
3. Follow 3-2-1—Plus Real Testing
Three copies of data, two types of media, one offsite or offline. But only count backups you’ve actually tested. If you test monthly, keep at least 30 days of dailies.
4. Know Where the Critical Data Lives
In OT, it’s not just files—it’s PLC programs, SCADA configs, HMI images, control logic. Document where it all resides and makes sure backups cover every essential piece.
5. Automate—But Verify
Manual backups are error-prone. Automate where possible, but don’t assume automation means reliability. Regularly verify backup status and contents.
6. Plan for Actual Recovery—Not Just Storage
Who restores what? In what order? On what hardware? Your recovery plan should be as detailed as your backup process. Backups are useless if you don’t have a working path to restoration.
Backup Strategy for Legacy OT Systems
Older systems bring unique risks to your OT disaster recovery strategy.
Why Legacy Backups Fail:
- No agent support: Older OSes like Windows XP or Unix variants can’t reliably run backup agents.
- Not virtualized: Without virtualization, hypervisor snapshots aren’t an option.
- Downtime is off-limits: These systems often run 24/7—any disruption carries operational risk.
What to Do Instead
- Use imaging-based tools that capture full disk snapshots without agents.
- Backup critical files like PLC configs or HMI logic if full imaging isn’t possible.
- Plan for longer recovery: Physical restoration takes time. Set realistic RTOs.
- Keep spare parts if hardware is obsolete—recovery may depend on them.
Your Partner for Secure, Reliable OT Backups
Many organizations in power and manufacturing industries turn to ProArch to ensure backups meet compliance requirements, especially under NERC CIP, BCSI, and other industrial cybersecurity standards. But compliance is just the floor.
ProArch’s OT Insights & Managed Services brings visibility into what really matters:
- Which systems are actually protected?
- Are your backups recent, isolated, and testable?
- Can you recover when it counts?
Our IT and OT experts connect your backup status to operational risk—giving you a clear view of coverage gaps, restore points, and recovery time across your OT environment. And it does it in real time, across vendors, platforms, and legacy systems.
Want to know if your OT backups are truly ready? Reach out to us.
Director of Marketing Rebecca leads ProArch's marketing efforts, seamlessly blending technology and storytelling to assist clients in their buying journey. She is dedicated to presenting technological solutions in a compelling manner that drives significant growth for the company. Collaborating closely with sales, engineering, leadership, and HR teams, Rebecca sets the strategic vision for ProArch and ensures alignment across the organization. Her strategic, visionary, and detail-oriented approach shapes ProArch’s brand to be synonymous with reimagining technology to achieve business objectives.