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Establishing a Technical Assistance Network to Build Capacity in Southwest Alaska (Southwest Alaska Energy Network - Final Report)

The Southwest Alaska Municipal Conference (SWAMC) is a non-profit regional membership economic development organization that represents the Aleutian/Pribilof Islands, Bristol Bay, and Kodiak regions of southwest Alaska. SWAMC applied for the DOE-OIE Establishment of an Inter-Tribal Technical Assistance Energy Providers Network grant FOA to work with our partners to provide energy planning and project development technical assistance. The project team was made up of SWAMC, three regional organizations, a management consulting firm, and a panel of technical consultants. SWAMC sub-contracted with the three Alaska Native regional non-profit organizations – Aleutian Pribilof Islands Association (APIA), Bristol Bay Native Association (BBNA), and Kodiak Area Native Association (KANA) – to fund full or partial Regional Energy Coordinator (REC) positions. The project period ran from September 2016 to March 2020. The project goal was to help southwest Alaska regional tribal partners and communities to develop efficient and financially sustainable structures for identifying and developing energy projects that enhance community resiliency and energy sustainability. This project established energy coordinators and management structures in the Aleutian, Bristol Bay, and Kodiak regions to expand technical assistance capacity of regional residents; demonstrate this capacity by advancing energy efficiency, heat, and power supply projects; and secure long-term funding commitments to establish a sustained technical assistance structure. The project team expanded technical assistance capacity of energy coordinators and regional stakeholders in several ways: by providing funding for the SWAMC project manager to attend three Office of Indian Energy trainings; for energy coordinators to attend numerous energy conferences; for utility clerks from several villages to receive one-on-one reporting training on Alaska’s Power Cost Equalization electric subsidy program; and for the Kodiak REC to complete the Arctic Remote Energy Networks Academy and NREL’s Executive Energy Leadership Academy. The energy coordinators demonstrated and shared their increased capacity by hosting several public events: SWAMC hosted two full-day energy workshops in February 2017 and 2018; the Kodiak REC hosted seven Energy Committee meetings for Kodiak stakeholders and gave several presentations at other events; and SWAMC and BBNA organized a Bristol Bay Regional Energy Visioning Session in May 2019. The project team created platforms to both share and request information to involve energy stakeholders in this project, including an energy website, a Facebook group, a periodic newsletter, surveys, mass emails, and paper mailers. An increase in regional capacity was demonstrated through several grant awards, including a $1.2 million USDA grant for Akhiok for an electric distribution infrastructure replacement; an AHFC Kickstarter grant for Aleknagik to audit 2 Tribal and 3 City buildings; and installation of an Air Source Heat Pump demonstration project in Atka. Two communities and one region – Ouzinkie (May 2017), Ugashik (July 2017), and the Bristol Bay region (May 2019) – utilized DOE’s technical assistance services to hold Strategic Energy Planning sessions with NREL and DOE facilitation assistance. And in early 2018, SWAMC established a parallel program, funded through a USDA Energy Audit and Renewable Energy Development grant to provide subsidized energy audits for small businesses in the region. SWAMC and partners have now completed energy audits of over 60 businesses (buildings and fishing vessels) and are currently operating a third round of the USDA program. Fifteen of those business owners have now received additional grant funding to cover 25% of the cost of the energy efficiency upgrades identified in the audit. This technical assistance structure will be sustained beyond DOE grant funding in several forms. As a sign of increased grant writing and project management capacity, the Kodiak Regional Energy Coordinator applied for and received a USDA Community Facilities Technical Assistance and Training grant to continue work begun under this program. Energy coordination tasks have been folded into existing economic development positions at SWAMC and at BBNA, ensuring long-term outreach and support in the region.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

A Comprehensive Economic Coal Transition in South Asia

Many countries are considering accelerating their coal transition. A coal transition refers to an energy sector’s shift from a reliance on coal toward an energy mix largely based on cleaner fuels and renewable energy sources. Such a transition is not just related to greenhouse gas emissions, but also encompasses a range of benefits, recognizing that global energy costs and options are changing. Since 2015, proposed new coal power capacity has dropped by three-quarters globally, leaving only a few countries that develop coal-fired power plants at scale (Littlecott et al., 2021). Historic steps were taken at the United Nations Climate Change 26th Conference of Parties (COP26) in Glasgow, as countries pledged to stop new coal builds, end international coal financing, phase down and phase out unabated coal use, and transition to clean energy. In South Asia, there have been several indicators suggesting that countries may be open to moving toward a coal transition. For example, the number of coal power plants under development across South Asia has decreased by 87% since 2015 (Littlecott et al., 2021). However, the challenges of assuring a just transition are substantial. Because coal plays a critical role in the energy and economic systems in South Asia, especially India, moving away from coal means realizing a broader country-wide economic and social transition. A comprehensive, integrated transition strategy for each state is thus needed urgently. This report briefly reviews the current trends and policies on coal in South Asian countries, develops a framework for a comprehensive economic coal transition, and assesses the opportunities and challenges of the transition in key countries. Several important findings emerge from the analysis. First, a coal transition can support overall economic growth and stability. Financial advantages to a well-planned coal transition include mitigating the risk of stranded assets and taking advantage of low-cost renewables. As a global coal transition proceeds, funds are being diverted from new unabated coal power plants, and utilization rates are declining. The likelihood that coal assets will become stranded is increasing, and the potential for future losses therefore increases as well. Second, coal imports in South Asia are rising. Of the coal consumed in Bangladesh, India, Nepal, and Sri Lanka, 32% is imported; this number increases to 94% when excluding India (International Energy Agency [IEA], 2021d). This illustrates a serious energy security risk. One example is the recent increase in coal prices in South Asia, to be discussed in Section 2.2.1. A diverse energy portfolio that incorporates local renewable energy can provide resilience in the face of changing commodity prices and availability. Third, the social benefits of a coal transition include positive health impacts and broader economic improvements in job creation, although assuring a just transition may be a challenge. Phasing out or phasing down coal can significantly reduce air pollutant emissions and therefore minimize associated premature mortality and improve life expectancy. Additional societal benefits of a coal transition include the high economy-wide potential for job creation, although it creates challenges in terms of reintegration and resettlement for coal miners and their communities.

01 COAL, LIGNITE, AND PEAT↗

Recycling polyolefin plastic waste at short contact times via rapid joule heating

Abstract The chemical deconstruction of polyolefins to fuels, lubricants, and waxes offers a promising strategy for mitigating their accumulation in landfills and the environment. Yet, achieving true recyclability of polyolefins into C 2 -C 4 monomers with high yields, low energy demand, and low carbon dioxide emissions under realistic polymer-to-catalyst ratios remains elusive. Here, we demonstrate a single-step electrified approach utilizing Rapid Joule Heating over an H-ZSM-5 catalyst to efficiently deconstruct polyolefin plastic waste into light olefins (C 2 -C 4 ) in milliseconds, with high productivity at much higher polymer-to-catalyst ratio than prior work. The catalyst is essential in producing a narrow distribution of light olefins. Pulsed operation and steam co-feeding enable highly selective deconstruction (product fraction of >90% towards C 2 -C 4 hydrocarbons) with minimal catalyst deactivation compared to Continuous Joule Heating. This laboratory-scale approach demonstrates effective deconstruction of real-life waste materials, resilience to additives and impurities, and versatility for circular polyolefin plastic waste management.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

FY2020 Technology Integration Annual Progress Report

The 2020 Technology Integration Annual Progress Report covers 46 multi-year projects funded by the Vehicle Technologies Office. The report includes information on competitively awarded projects, ranging from rural shared mobility demonstration projects to medium- and heavy-duty electric vehicle deployment to statewide alternative fuel resiliency planning. It also includes projects conducted by several of the Vehicle Technologies Office’s (VTO) National Laboratory partners, Argonne National Laboratory, Oak Ridge National Laboratory and the National Renewable Energy Laboratory. These projects range from a Technical Assistance project for business, industry, government and individuals, to the EcoCar Advanced Vehicle Technology Competition, and the Fuel Economy Information Project.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

WIP: Collaborating to Introduce Second-Life Battery Technology Research in an Informal STEM Learning Environment

This work in progress, innovative practice, paper outlines an interdisciplinary collaborative model utilized by a team of educational researchers, and engineers to design a series of community-centered, place-based learning activities suitable for a middle or high school informal STEM learning environment. Based on the potential applications and benefits of Second-Life Electric Vehicle Batteries, the activities connect cutting-edge STEM research with multidimensional real-world challenges within their communities related to climate change, renewable energy integration and storage, intelligent transportation systems, and optimized energy management, that empowers students to think critically about the role they can play in shaping a more resilient, environmentally sustainable community.

Whiteside, Hope↗

Water Security: Trends, Capabilities, and Research Directions to Secure Water Infrastructure

Water and wastewater sector is target rich and resource poor ~153k water utilities, serve 80% of US population ~16k publicly-owned wastewater systems in the US serve 75% of the population Need scalable solutions to fit small and medium to large systems Federal attention to critical infrastructure continues to grow – particularly in the water sector Increase in water sector incidents and threats for large scale disruption – particularly by nation-state actors and their proxies EPA is the SRMA DHS CISA focuses on critical infrastructure protection across sectors They must work together to secure WWW systems Research capabilities to enable secure water systems Current and future threats Resilience – natural disasters, accidents, cyber-physical attacks

99 - GENERAL AND MISCELLANEOUS↗

Structure-property relationships and recyclability of natural fiber insulation

Thermal insulation can significantly decrease the energy required to maintain internal temperatures within buildings, saving money and decreasing environmental impacts. Many industrially available insulation options utilize petroleum-derived materials, such as polyurethane, fiberglass, and polystyrene, which can be detrimental to the environment by emitting greenhouse gases during production. A sustainable alternative to these synthetic insulations is the use of renewable feedstocks to produce comparable insulation products. In this work, natural fibers such as flax and banana were bound with an epoxy system to produce natural-fiber insulation. Key experimental parameters for this study included evaluating the fiber lengths and processing methods while varying the viscosity of the epoxy binder solvent dissolution. Insulation performance was determined by comparing density, thermal conductivity, resilience, and compressive strength; these parameters were tested to further understand and investigate the structure- property relationships within the system and to understand how these composites compare to current commercial materials. Furthermore, from this characterization and optimization, a natural fiber sample with an R/in. >5 was achieved, making these materials competitive with commercial alternatives.

Compressive strength↗

Enabling end-to-end secure federated learning in biomedical research on heterogeneous computing environments with APPFLx

Facilitating large-scale, cross-institutional collaboration in biomedical machine learning (ML) projects requires a trustworthy and resilient federated learning (FL) environment to ensure that sensitive information such as protected health information is kept confidential. Specifically designed for this purpose, this work introduces APPFLx - a low-code, easy-to-use FL framework that enables easy setup, configuration, and running of FL experiments. APPFLx removes administrative boundaries of research organizations and healthcare systems while providing secure end-to-end communication, privacy-preserving functionality, and identity management. Furthermore, it is completely agnostic to the underlying computational infrastructure of participating clients, allowing an instantaneous deployment of this framework into existing computing infrastructures. Experimentally, the utility of APPFLx is demonstrated in two case studies: (1) predicting participant age from electrocardiogram (ECG) waveforms, and (2) detecting COVID-19 disease from chest radiographs. Here, ML models were securely trained across heterogeneous computing resources, including a combination of on-premise high-performance computing and cloud computing facilities. By securely unlocking data from multiple sources for training without directly sharing it, these FL models enhance generalizability and performance compared to centralized training models while ensuring data remains protected. In conclusion, APPFLx demonstrated itself as an easy-to-use framework for accelerating biomedical studies across organizations and healthcare systems on large datasets while maintaining the protection of private medical data.

Biomedical Research↗

An extended radar relative calibration adjustment (eRCA) technique for higher-frequency radars and range–height indicator (RHI) scans

Abstract. This study extends the relative calibration adjustment technique for calibration of weather radars to higher-frequency radars as well as range–height indicator (RHI) scans. The calibration of weather radars represents one of the most dominant sources of error for their use in a variety of fields including quantitative precipitation estimation and model comparisons. While most weather radars are routinely calibrated, the frequency of calibration is often less than required, resulting in miscalibrated time periods. While full absolute calibration techniques often require the radar to be taken offline for a period of time, there have been online calibration techniques discussed in the literature. The relative calibration adjustment (RCA) technique uses the statistics of the ground clutter surrounding the radar as a monitoring source for the stability of calibration but has only been demonstrated to work at S- and C-band for plan-position indicator (PPI) scans at a constant elevation. In this work the RCA technique is modified to work with higher-frequency radars, including Ka-band cloud radars. At higher frequencies the properties of clutter can be much more variable. This work introduces an extended clutter selection procedure that incorporates the temporal stability of clutter and helps to improve the operational stability of RCA for relatively higher-frequency radars. The technique is also extended to utilize range–height scans from radars where the elevation is varied rather than the azimuth. These types of scans are often utilized with research radars to examine the vertical structure of clouds. The newly extended technique (eRCA) is applied to four Department of Energy Atmospheric Radiation Measurement (DOE ARM) weather radars ranging in frequency from C- to Ka-band. Cross comparisons of three co-located radars with frequencies C, X, and Ka at the ARM Cloud, Aerosol, and Complex Terrain Interactions (CACTI) site show that the technique can determine changes in calibration. Using an X-band radar at the ARM Eastern North Atlantic (ENA) site, we show how the technique can be modified to be more resilient to clutter fields that show increased variability, in this case due to sea clutter. The results show that this technique is promising for a posteriori data calibration and monitoring.

47 OTHER INSTRUMENTATION↗

Integrated Energy Systems Program Management Plan

In 2012, the U.S. Department of Energy (DOE) Office of Nuclear Energy (NE) initiated the Nuclear Energy Enabling Technology Program, which includes the Crosscutting Technology Development (CTD) portfolio of subprograms, to conduct research, development, and demonstration (RD&D) to support existing, new and advanced reactor designs and fuel cycle technologies. This program plan describes the Integrated Energy Systems (IES) Program, an element of the CTD portfolio since 2016 that seeks to improve the economic competitiveness, efficiency and environmental performance of nuclear energy systems by expanding their potential application space beyond electricity and optimizing their utilization in the context of the larger U.S. electric and non-electric energy system.

08 HYDROGEN↗

Autonomous System Technologies for Resilient Airspace Operations

Increasing autonomous systems within the aircraft cockpit begins with an effort to understand what autonomy is and developing the technology that encompasses it. Autonomy allows an agent, human or machine, to act independently within a circumscribed set of goals; delegating responsibility to the agent(s) to achieve overall system objective(s). Increasingly Autonomous Systems (IAS) are the highly sophisticated progression of current automated systems toward full autonomy. Working in concert with humans, these types of technologies are expected to improve the safety, reliability, costs, and operational efficiency of aviation. IAS implementation is imminent, which makes the development and the proper performance of such technologies, with respect to cockpit operation efficiency, the management of air traffic and data communication information, vital. A prototype IAS agent that attempts to optimize the identification and distribution of "relevant" air traffic data to be utilized by human crews during complex airspace operations has been developed.

Houston, Vincent E.↗

Response of fs-Laser-Irradiated Diamond by Ultrafast Electron Diffraction

Structural details of the proposed solid–liquid phase transition of carbon have remained elusive, despite years of study. While it is theorized that novel carbon materials form from a liquid precursor, experimental studies have lacked the temporal and spatial resolution necessary to fully characterize the purported liquid state. Here, in this work, we utilize megaelectronvolt-ultrafast electron diffraction (MeV-UED) to study laser irradiated submicron diamond thin films in a pump–probe scheme with picosecond time resolution to visualize potential structural changes of excited diamond. We probe the structure of diamond using a combination of fluences (13, 40 J/cm 2 ) and time delays (10, 25, 100 ps), but observe negligible changes in the static diffraction pattern of diamond and an overall decrease in diffraction intensity up to 100 ps after the excitation pulse. We thus conclude that no appreciable amount of liquid or graphitized carbon is present and highlight the structural resilience of bulk diamond to intense 800 nm ultrafast laser pulses.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Integrating AI Data Centers with the Power Grid

The rapid expansion of artificial intelligence (AI) has triggered an unprecedented surge in electricity demand, with US data center energy use projected to double or triple 2023 levels by 2028. This exponential growth places strain on grid infrastructure, which can hinder timely construction of desired computing capacity. To bridge this supply-demand gap, utilities and AI developers are increasingly turning to demand flexibility, a strategy that incentivizes shifting or reducing power use during peak periods of grid stress. Data centers are uniquely equipped for flexible operations due to their digital workloads, built-in redundancy, and onsite energy assets. This article outlines four primary mechanisms to enable data center flexibility: computational load flexibility (shifting tasks temporally or geographically), flexible use of core facility infrastructure adjustments, energy storage utilization, and onsite electricity generation. To encourage adoption, utilities are deploying new tariff designs, including voluntary interruptible service riders, mandated flexibility requirements, and streamlined interconnection processes for flexible loads. For the highly capitalized and rapidly growing AI industry, the primary motivators for embracing these strategies are expediting facility interconnection, satisfying emerging regulatory mandates, and mitigating community resistance. While demand flexibility cannot substitute the long-term need for new bulk power generation, it serves as an essential, immediate solution for enabling near-term deployment. By transforming data centers from grid stressors into stabilizing assets, flexible operations can ensure reliable grid integration, ease market pressures, and support a resilient power system.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Regulatory and Technical Challenges and Barriers to Adoption of Distributed Wind Energy in Agricultural Settings

Distributed wind (DW) energy development can benefit agricultural landowners through the possibility of improved resilience of electrical service from onsite generation and associated economic benefits. DW development currently faces technical and regulatory challenges related to interconnection of projects with distribution or transmission equipment on the main electrical grid. A review was conducted of barriers to adoption for agricultural DW projects and potential roles of various stakeholders in addressing them. One major barrier is that the unique characteristics of wind energy generation such as its variability and intermittency, may require upgrades for the whole power line, which can lead to prohibitive cost burdens on individual interconnection customers. Another barrier is compliance with federal, state, or utility-level regulations that require technology-agnostic, industry-standard equipment that is often not technically realistic for DW projects. DW developers, grid infrastructure owner-operators, regulators, and standards publishers can work together to address these challenges and facilitate DW development.

17 WIND ENERGY↗

The Essential Role of Nuclear Energy in Achieving Economy-wide Net-Zero Solutions

Governments and private industry around the world have established aggressive goals to achieve net-zero emissions for the power, industrial, and transportation sectors by 2050. These aggressive goals demand immediate action if we are to be successful, and they require us to think more holistically about our clean energy options. Programs within the U.S. Department of Energy (DOE) are addressing these holistic solutions. Traditionally, electricity generation and management and meeting energy demands for industry and transportation are considered independently. As we seek to achieve net-zero, we need to reassess energy demands. When we consider overall energy use, only one-third is in the form of electricity. Additional energy demands are in the form of heat or steam for industrial processes, as well as transportation. These sectors are much harder to abate, and electrification may not be the best option. Reducing environmental emissions at an affordable cost, while maintaining grid reliability and resilience, will require us to use all of the clean energy resources that we have available. That means coordinating the use of nuclear, renewables, and fossil fuels with carbon capture to meet growing demands for electricity, industrial applications, and mobility. The DOE Office of Nuclear Energy (DOE-NE) program on Integrated Energy Systems (IES) is led by researchers at Idaho National Laboratory (INL) and work is conducted in partnership with an array of other DOE laboratories, industry, and academia. The primary focus of IES research is to assess the technical and economic potential of IES to enhance the flexibility and utilization of nuclear reactors working alongside renewable generators to meet an array of energy demands—thereby maximizing the utilization of clean energy resources across all energy sectors. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and chemicals. The DOE-NE program additionally partners with the Hydrogen and Fuel Cell Technologies Office under the DOE Office of Energy Efficiency and Renewable Energy to jointly fund the development of analysis tools, technologies, and nuclear-integrated hydrogen demonstration projects. This presentation highlights the wide array of R&D being conducted across multiple DOE-funded programs to develop and deploy nuclear-based IES that will be key to achieving our net-zero goals. By working with key collaborators in the nuclear industry, analytical studies are now becoming a reality in demonstration projects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Advancing Nuclear Energy to Support Economy-wide Net-zero Solutions: Challenges and Opportunities

Governments and private industry around the world have established aggressive goals to achieve net-zero emissions for the power, industrial, and transportation sectors by 2050. These aggressive goals demand immediate action if we are to be successful, and they require us to think more holistically about our clean energy options. Programs within the U.S. Department of Energy (DOE) are addressing these holistic solutions. Traditionally, electricity generation and management and meeting energy demands for industry and transportation are considered independently. As we seek to achieve net-zero, we need to reassess energy demands. When we consider overall energy use, only one-third is in the form of electricity. Additional energy demands are in the form of heat or steam for industrial processes, as well as transportation. These sectors are much harder to abate, and electrification may not be the best option. Reducing environmental emissions at an affordable cost, while maintaining grid reliability and resilience, will require us to use all of the clean energy resources that we have available. That means coordinating the use of nuclear, renewables, and fossil fuels with carbon capture to meet growing demands for electricity, industrial applications, and mobility. The DOE Office of Nuclear Energy (DOE-NE) program on Integrated Energy Systems (IES) is led by researchers at Idaho National Laboratory (INL) and work is conducted in partnership with an array of other DOE laboratories, industry, and academia. The primary focus of IES research is to assess the technical and economic potential of IES to enhance the flexibility and utilization of nuclear reactors working alongside renewable generators to meet an array of energy demands—thereby maximizing the utilization of clean energy resources across all energy sectors. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and chemicals. The DOE-NE program additionally partners with the Hydrogen and Fuel Cell Technologies Office under the DOE Office of Energy Efficiency and Renewable Energy to jointly fund the development of analysis tools, technologies, and nuclear-integrated hydrogen demonstration projects. This presentation highlights the wide array of R&D being conducted across multiple DOE-funded programs to develop and deploy nuclear-based IES that will be key to achieving our net-zero goals. By working with key collaborators in the nuclear industry, analytical studies are now becoming a reality in demonstration projects. The presentation specifically focuses on motivations for the paradigm shift in how nuclear energy is deployed and used, opportunities for nuclear energy to support an array of non-electric application, integration options, computational tools and experimental systems to support evaluation and to accelerate deployment, and industry partnerships.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Advanced Transmission Technologies (ATTs) Supplier Cohort Workshops Cohort Summary [Slides]

This Summary slide deck summarizes the key outcomes of the Advanced Transmission Technologies (ATTs) supplier cohort, part of Idaho National Laboratory’s (INL) Technical Assistance for Digital Assurance (TADA) program. The program aimed to strengthen grid resilience through cybersecurity controls, supply-chain security, and Cyber-Informed Engineering (CIE) for advanced transmission technologies. The cohort brought together vendors representing the full range of Grid-Enhancing Technologies (GETs), including providers of Dynamic Line Ratings (DLR), Advanced Power Flow Control (APFC), Transmission Topology Optimization (TTO), and High-Performance Conductors (HPCs). Discussions focused on institutional, integration, and operational barriers limiting GET adoption; cybersecurity risks at EMS/SCADA, cloud, and network integration points; and supply-chain transparency issues such as semiconductor dependence and SBOM/HBOM expectations. Participants also addressed operator trust, human-in-the-loop requirements, and challenges with utility adoption, while exploring how CIE can support secure deployment of GETs. This deck represents a consolidated summary of challenges and risks identified by vendors, cross-cutting themes and technology-specific insights from three cohort workshops, and actionable mitigations to guide utilities, vendors, and the Department of Energy in advancing secure, trusted deployment of GETs.

24 - POWER TRANSMISSION AND DISTRIBUTION↗

Exponential Backoff and Its Security Implications for Safety-Critical OT Protocols over TCP/IP Networks

The convergence of Operational Technology (OT) and Information Technology (IT) networks has become increasingly prevalent with the growth of Industrial Internet of Things (IIoT) applications. This shift, while enabling enhanced automation, remote monitoring, and data sharing, also introduces new challenges related to communication latency and cybersecurity. Oftentimes, legacy OT protocols were adapted to the TCP/IP stack without an extensive review of the ramifications to their robustness, performance, or safety objectives. To further accommodate the IT/OT convergence, protocol gateways were introduced to facilitate the migration from serial protocols to TCP/IP protocol stacks within modern IT/OT infrastructure. However, they often introduce additional vulnerabilities by exposing traditionally isolated protocols to external threats. This study investigates the security and reliability implications of migrating serial protocols to TCP/IP stacks and the impact of protocol gateways, utilizing two widely used OT protocols: Modbus TCP and DNP3. Our protocol analysis finds a significant safety-critical vulnerability resulting from this migration, and our subsequent tests clearly demonstrate its presence and impact. A multi-tiered testbed, consisting of both physical and emulated components, is used to evaluate protocol performance and the effects of device-specific implementation flaws. Through this analysis of specifications and behaviors during communication interruptions, we identify critical differences in fault handling and the impact on time-sensitive data delivery. The findings highlight how reliance on lower-level IT protocols can undermine OT system resilience, and they inform the development of mitigation strategies to enhance the robustness of industrial communication networks.

DNP3↗