Introduction

Petrochemical cracking units are critical processing systems used to convert hydrocarbon feedstocks into valuable chemical building blocks such as ethylene, propylene, and other olefin products. Cracking operations involve complex equipment and tightly controlled process conditions, including high temperatures, pressures, feed rates, furnace operation, compression, cooling, and downstream separation.

Texas City has a long-established chemical and petrochemical industrial presence, with public records identifying numerous chemical facilities and industrial operations in the area. Current TCEQ records include Texas City chemical facilities and olefin-related operations, while public technical documentation describes cracking processes in which feedstocks are converted into olefins and subsequently processed through compression, chilling, distillation, and purification stages.

Modern cracking units depend extensively on Operational Technology (OT) to maintain stable and continuous production. Distributed Control Systems (DCS), Programmable Logic Controllers (PLC), Human Machine Interfaces (HMI), engineering workstations, industrial networks, process historians, sensors, actuators, and remote access systems work together to monitor and control the process.

A cybersecurity weakness within these interconnected systems can affect process visibility, control integrity, equipment availability, or communication between critical assets. An OT Security Assessment helps petrochemical organizations identify vulnerabilities across their cracking-unit environment and develop practical measures to strengthen the security of critical industrial systems.

Importance of OT Security Assessment for Petrochemical Cracking Units

Cracking units require continuous coordination between process equipment and control systems. A change in furnace conditions, feed composition, temperature, pressure, flow, or compression can influence downstream operations.

The OT environment therefore needs appropriate security controls to protect critical systems and maintain reliable process operations. A structured assessment provides visibility into the technologies supporting the cracking process and identifies weaknesses that may increase operational exposure.

1. Protecting Cracking Furnace Operations

Cracking furnaces operate under tightly controlled process conditions. Control systems continuously monitor process parameters and adjust equipment according to configured operating requirements.

Security weaknesses affecting controller logic, engineering access, process configurations, or communication pathways can introduce risks to automated operations.

The assessment can helps to identify weaknesses that could affect the integrity and availability of furnace-control operations.

2. Securing DCS and PLC Infrastructure

DCS and PLC systems play an important role in monitoring and controlling industrial processes. Engineering workstations and control servers provide additional functionality for configuration, maintenance, and system administration.

An OT Security Assessment helps to identify vulnerabilities that could expose critical control components to unauthorized access or modification.

3. Protecting Compression and Chilling Systems

After the cracking stage, process streams can move through compression and chilling operations before downstream separation. These systems depend on coordinated monitoring and control of equipment such as compressors, refrigeration systems, valves, and instrumentation. Public technical documentation for petrochemical cracking operations describes cracking followed by compression and chilling before downstream distillation and separation.

Cybersecurity weaknesses in control systems supporting these processes could affect monitoring, equipment coordination, or process data integrity.

4. Securing Industrial Network Architecture

Industrial networks connect controllers, HMIs, engineering workstations, servers, historians, network devices, and other OT components.

Weak segmentation or unnecessary communication pathways can increase the exposure of critical cracking-unit systems.

The assessment helps to identify weaknesses that could increase unauthorized access or movement within the industrial environment.

5. Managing Remote and Third-Party Access

Remote access can be used by plant personnel, equipment vendors, system integrators, and maintenance teams for troubleshooting, engineering support, and technical maintenance.

Without appropriate controls, these connections can create additional entry points into the OT environment.

Our OT Security Assessment Methodology

Petrochemical cracking units require a controlled assessment approach because their OT systems are closely connected to physical processes and industrial equipment.

The methodology focuses on understanding the OT environment, identifying vulnerabilities, reviewing security controls, and providing practical remediation guidance while considering operational continuity.

1. Scope and Assessment Planning

The assessment begins by establishing the systems, process areas, assets, and network segments included within the agreed scope.

Planning considers:

• Cracking-unit architecture
• Critical OT assets
• DCS and PLC systems
• HMI and SCADA infrastructure
• Engineering workstations
• Industrial network boundaries
• Remote access systems
• Authorized testing activities
• Operational constraints

A defined scope helps ensure that assessment activities remain focused and controlled.

2. Asset and Architecture Discovery

The next stage focuses on understanding the technologies supporting the cracking process.

Assets may include DCS servers, PLCs, HMIs, engineering workstations, historians, industrial switches, firewalls, remote access gateways, and supporting OT infrastructure.

The assessment maps relevant relationships and communication pathways to understand critical dependencies and identify unnecessary connections.

3. Industrial Network Security Assessment

The industrial network is evaluated to understand how critical systems communicate across the cracking-unit environment.

The review examines network architecture and security controls across relevant OT zones.

Key areas include:

• Network segmentation
• Firewall rules
• Industrial protocols
• Switch configurations
• Access controls
• Communication pathways
• Network exposure
• IT and OT connectivity
• Monitoring and logging

This helps identify weaknesses that could allow unauthorized access to critical OT assets.

4. OT Vulnerability Assessment

The OT Vulnerability Assessment identifies technical vulnerabilities and insecure configurations affecting industrial systems.

Depending on the approved scope, the assessment may review:

• Vulnerable software versions
• Exposed ports and services
• Insecure configurations
• Weak authentication
• Unsupported systems
• Excessive privileges
• Misconfigured network devices
• Unnecessary services

Testing techniques are selected according to the sensitivity and operational characteristics of the cracking environment.

5. DCS and PLC Security Assessment

DCS and PLC systems are central to automated cracking operations.

The assessment reviews security controls around controllers, control servers, engineering workstations, communication pathways, and configuration management.

Areas of focus include:

• Controller configurations
• DCS architecture
• PLC communication
• Engineering access
• Administrative privileges
• Control logic protection
• Configuration management
• Change controls

The objective is to identify weaknesses that could affect automated process operations.

6. SCADA and HMI Security Assessment

HMI systems allow operators to monitor process conditions and interact with authorized industrial controls. Where SCADA systems are used, they can provide additional supervisory monitoring and data-management functions.

The assessment examines:

• HMI configurations
• SCADA servers
• Operator authentication
• User privileges
• Exposed services
• Workstation security
• Communication pathways
• Alarm and monitoring interfaces

This helps identify weaknesses that could affect operator visibility or unauthorized interaction with critical systems.

7. Access and Configuration Review

Access controls are reviewed to determine whether users and administrators have appropriate permissions within the OT environment.

The assessment evaluates:

• User accounts
• Privileged accounts
• Password controls
• Inactive accounts
• Remote access permissions
• Administrative access
• System hardening
• Security configurations
• Unnecessary services

Reducing unnecessary privileges and improving system configurations can help reduce exposure across critical OT assets.

8. Risk Analysis and Reporting

The final stage brings together technical findings and their potential operational relevance.

Each finding is documented with information such as:

• Affected asset
• Identified vulnerability
• Configuration weakness
• Technical evidence
• Potential impact
• Risk context
• Recommended remediation
• Suggested remediation priority

The final report provides plant, engineering, and security teams with actionable information for strengthening the OT environment.

Cyberintelsys OT Security Services

Cyberintelsys delivers OT security assessment services for industrial environments where cybersecurity needs to be considered alongside operational continuity.

1. OT Vulnerability Assessment

An OT Vulnerability Assessment identifies technical vulnerabilities and security weaknesses across industrial assets supporting petrochemical cracking operations.

Coverage can include:

• DCS infrastructure
• PLCs and controllers
• HMI systems
• SCADA servers
• Engineering workstations
• Industrial servers
• Network devices
• Supporting OT systems

Findings are documented with practical recommendations to help organizations address identified weaknesses.

2. OT VAPT

OT VAPT combines vulnerability assessment with controlled penetration testing techniques to identify weaknesses and potential attack paths within the approved scope.

Testing is planned around the operational characteristics of the cracking unit to minimize unnecessary disruption to critical processes.

3. Industrial Network Security Assessment

Industrial Network Security Assessment examines the communication infrastructure connecting critical OT assets.

The service evaluates network segmentation, firewall controls, access restrictions, industrial communication pathways, network exposure, and connectivity between operational zones.

4. DCS and PLC Security Assessment

DCS and PLC Security Assessment focuses on systems responsible for monitoring and controlling critical cracking-unit processes.

The assessment examines controller configurations, engineering workstations, control logic access, communication mechanisms, administrative privileges, and configuration-management practices.

5. SIS Security Assessment

Where Safety Instrumented Systems are deployed, the assessment reviews relevant architecture, access controls, configurations, connectivity, and supporting infrastructure.

Testing is approached carefully to avoid unnecessary interference with safety-related functions.

6. SCADA and HMI Security Assessment

SCADA and HMI Security Assessment examines operator interfaces and supervisory systems supporting process monitoring and control.

The review considers authentication, authorization, system configuration, exposed services, workstation security, and communication pathways.

7. Remote Access Security Assessment

Remote Access Security Assessment focuses on pathways used by employees, vendors, contractors, and maintenance teams to connect to OT systems.

The assessment examines:

• Authentication
• Authorization
• Account permissions
• Remote sessions
• Access restrictions
• Network pathways
• Third-party connectivity

Why Choose Cyberintelsys

Petrochemical cracking units require an OT security approach that understands the relationship between industrial automation, process control, network architecture, and operational continuity.

Cyberintelsys focuses on identifying vulnerabilities across the OT environment while considering the technologies and communication pathways supporting critical petrochemical operations.

Cyberintelsys is a CREST-accredited cybersecurity company for Vulnerability Assessment (VA) and Penetration Testing (PT), delivering industry-recognized security testing services for organizations across multiple sectors.

Key areas include:

• OT vulnerability identification
• Industrial network security assessment
• DCS and PLC security assessment
• SCADA and HMI security assessment
• Remote access security assessment
• Engineering workstation security
• Access and configuration reviews
• Risk-based reporting
• Practical remediation guidance

The objective is to help organizations gain greater visibility into their OT security posture and identify areas where security controls can be strengthened.

Contact Cyberintelsys

Petrochemical cracking units depend on reliable automation, accurate process measurements, secure industrial networks, and controlled access to critical operational assets. As cracking and downstream processing environments become increasingly connected, identifying cybersecurity weaknesses across these systems is an important part of protecting operational continuity.

Organizations operating petrochemical cracking units in Texas City can work with Cyberintelsys to assess their OT infrastructure, identify vulnerabilities, review industrial network security, and strengthen controls across critical process-control systems.

Strengthen your industrial cybersecurity posture with a structured OT Security Assessment designed for your petrochemical cracking environment.

Contact Cyberintelsys to discuss your OT security assessment requirements.