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DOE OSTI2026

Modular Accelerator Robotics Framework Implementation For Accelerator Inspection

Accelerator tunnels, such as the ones at Fermilab, remain highly radioactive after beam shutoff due to induced radiation from the beam. This residual radiation creates a hazardous environment for manual inspection and repair of beamline components. To minimize worker radiation dose and reduce beam downtime, the AD Robotics Initiative previously built a fleet of low-cost custom mobile robots. However, the custom Python sockets server-client architecture lacked standardization, causing development delays and complicating the integration of new sensors and actuators. Here, we developed a modular system using ROS2 and Docker to standardize the teleoperation and control interfaces. This system was validated by implementing a teleoperation controller with real-time, low-latency, and high-definition video feedback. The aim of this framework is for a new feature or even a robot to be integrated into the system simply by documenting the hardware configuration. Current integration of LiDAR, Odometry, and Depth Cameras provides the foundation for Simultaneous Localization and Mapping (SLAM) tasks. Finally, future work involves integration into the accelerator control system and the attachment of a 6 degree-of-freedom robotic arm for telemanipulation.

Rayyan Khana, M. [Unlisted, US, IL] (ORCID:0009000↗

DOE OSTI2023

Reflective Fiber Temperature Probe Based on Localized Surface Plasmon Resonance towards Low-Cost and Wireless Interrogation

Reflection fiber temperature sensors functionalized with plasmonic nanocomposite material using intensity-based modulation are demonstrated for the first time. Characteristic temperature optical response of the reflective fiber sensor is experimentally tested using Au-incorporated nanocomposite thin films deposited on the fiber tip, and theoretically validated using a thin-film-optic-based optical waveguide model. By optimizing the Au concentration in a dielectric matrix, Au nanoparticles (NP) exhibit a localized surface plasmon resonance (LSPR) absorption band in a visible wavelength that shows a temperature sensitivity ~0.025%/°C as a result of electron–electron and electron–phonon scattering of Au NP and the surrounding matrix. Detailed optical material properties of the on-fiber sensor film are characterized using scanning electron microscopy (SEM) and focused-ion beam (FIB)-assisted transmission electron microscopy (TEM). Airy’s expression of transmission and reflection using complex optical constants of layered media is used to model the reflective optical waveguide. A low-cost wireless interrogator based on a photodiode transimpedance-amplifier (TIA) circuit with a low-pass filter is designed to integrate with the sensor. The converted analog voltage is wirelessly transmitted via 2.4 GHz Serial Peripheral Interface (SPI) protocols. Feasibility is demonstrated for portable, remotely interrogated next-generation fiber optic temperature sensors with future capability for monitoring additional parameters of interest.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Energy consumption and cooperation for optimal sensing

Abstract The reliable detection of environmental molecules in the presence of noise is an important cellular function, yet the underlying computational mechanisms are not well understood. We introduce a model of two interacting sensors which allows for the principled exploration of signal statistics, cooperation strategies and the role of energy consumption in optimal sensing, quantified through the mutual information between the signal and the sensors. Here we report that in general the optimal sensing strategy depends both on the noise level and the statistics of the signals. For joint, correlated signals, energy consuming (nonequilibrium), asymmetric couplings result in maximum information gain in the low-noise, high-signal-correlation limit. Surprisingly we also find that energy consumption is not always required for optimal sensing. We generalise our model to incorporate time integration of the sensor state by a population of readout molecules, and demonstrate that sensor interaction and energy consumption remain important for optimal sensing.

Ngampruetikorn, Vudtiwat↗

DOE OSTI2026

Desert-Urban System Integrated Atmospheric Monsoon (DUSTIEAIM) in the Southwestern United States Science Plan

The Desert-Urban System Integrated Atmospheric Monsoon (DUSTIEAIM) campaign is a groundbreaking, high-impact scientific mission that will transform how we understand and respond to energy and water challenges in one of America’s fastest-growing and most heat-stressed urban regions: Phoenix, Arizona. Starting in April 2026, this 18-month field campaign harnesses the full power of the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility and an interdisciplinary science team including national laboratories, universities, and agencies with a broad range of subject-matter expertise. With cutting-edge instruments, active and passive ground-based sensors, radars, and integrated modeling, DUSTIEAIM will deliver the most comprehensive environmental data set ever collected for a desert-urban-agricultural interface.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

The LED calibration systems for the mDOM and D-Egg sensor modules of the IceCube Upgrade: Design, production, testing and use in module calibration

The IceCube Neutrino Observatory, instrumenting about 1 km 3 of deep, glacial ice at the geographic South Pole, is due to be enhanced with the IceCube Upgrade. The IceCube Upgrade, to be deployed during the 2025/26 Antarctic summer season, will consist of seven new strings of photosensors, densely embedded near the bottom center of the existing array. Aside from a world-leading sensitivity to neutrino oscillations, a primary goal is the improvement of the calibration of the optical properties of the instrumented ice. This calibration will be applied to the entire archive of IceCube data, improving the angular and energy resolution of the detected neutrino events. For this purpose, the Upgrade strings include a host of new calibration devices. Aside from dedicated calibration modules, several thousand LED flashers have been incorporated into the photosensor modules. We describe the design, production, and testing of these LED flashers before their integration into the sensor modules as well as the use of the LED flashers during lab testing of assembled sensor modules.

Analogue electronic circuits↗

DOE OSTI2026

IPC-Fusion (Infrastructure Perception and Control (IPC): Multisensor Data Fusion Software) [SWR-25-153]

As part of the National Laboratory of the Rockies' (NLR’s) Infrastructure Perception and Control Laboratory, the IPC-Fusion toolkit provides a probabilistic, scalable, multi-sensor fusion framework that integrates (late-stage fusion) heterogeneous object detection data from traffic sensors to enable robust, real-time tracking of roadway occupants. The algorithmic design of the toolkit is motivated by the need for creating a digital twin of traffic at the edge in a scalable and affordable manner. The software operates by combining object-level measurements (such as position and velocity) from a suite of sensors (such as radar, lidar, camera) using Kalman filtering and probabilistic data association techniques to overcome individual sensor limitations and achieve superior tracking performance in complex traffic zones. The framework addresses key challenges including heterogeneous measurement uncertainties, asynchronous data streams, varying spatiotemporal data resolutions, robust data association, and adaptive object lifecycle management. Validated on real-world traffic intersection data including vehicles and pedestrians, IPC-Fusion demonstrates enhanced tracking reliability across scenarios involving occlusions, sensor failures, and varying traffic densities, supporting the broader IPC initiative's goal of transforming transportation infrastructure through advanced perception capabilities for intelligent transportation systems, traffic safety applications, and autonomous vehicle support.

Sandhu, Rimple [National Laboratory of the Rockies↗

DOE OSTI2023

Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays

This is the final technical report for the Virginia Tech Center for Photonics Technology (VT-CPT) research project entitled “Fully Distributed Acoustic and Magnetic Field Monitoring Via a Single Fiber Line for Optimized Production of Unconventional Resource Plays”. In the the four-year effort, VT-CPT collaborated with the Departments of Mathmatics at VT and Sentek Instrument, LLC (Sentek) to develop a fiber-optic sensing system capable of real-time simultaneous distributed measurement of multiple subsurface, drilling, and production parameters. The ultra-sensitive fiber optic distributed acoustic sensing technology, picoDAS, developed by Sentek was integrated with a novel multi-material optical sensing fiber fabricated by CPT-VT to obtain distributed acoustic and magnetic field measurements with ultrahigh sensitivity and high spatial resolution. The sensing technology successfully developed and demonstrated under this research program is truly unique has application beyond subsurface imaging to include carbon storage and electrical grid monitoring, as well as healthcare and nuclear fusion. The project, sponsored by the Advanced Technology Program, began in 2019 and had the original goal of developing the next generation of harsh environment sensing systems. Exhaustive theoretical modeling was performed to optimize the multi-material optical fiber design. VT developed the processing techniques employed to successfully fabricate single mode fibers with metal cladding wires. Sensing fibers with nickel and Metglas cladding wires were fully characterized, inscribed with sensors, and fully integrated with the picoDAS system. Laboratory scale testing was performed to demonstrate performance upon exposure to lateral and transverse magnetic fields. Preliminary field trials were performed for prototype magnetic and acoustic sensing systems upon near surface deployment at VT. The distributed acoustic and magnetic field sensing system was advanced from a (Technology Readiness Level) TRL=2 to a TRL=5 via laboratory scale system validation in relevant environments. The truly one-of-its kind distributed magnetic and acoustic sensing system is expected to find immediate applications that require subsurface monitoring, to include carbon storage site monitoring, and has the potential to be a distributive technology in healthcare and electric grid markets. The technologies developed by Virginia Tech’s Center for Photonics Technology will support the mission of the National Energy Technology Laboratory (NETL) to drive innovation and deliver solutions for an environmentally sustainable and prosperous energy future by ensuring affordable, abundant, and reliable energy that drives a robust economy and national security. Technical accomplishments during the program are summarized briefly here and described in detail in the remainder of the report.

02 PETROLEUM↗

DOE OSTI2024

Electrical design of the flexible imaging diffraction diagnostic for laser experiments (FIDDLE) at the National Ignition Facility (NIF)—Requirements, design, and performance

The Flexible Imaging Diffraction Diagnostic for Laser Experiments (FIDDLE) is a newly developed diagnostic for imaging time resolved diffraction in experiments at the National Ignition Facility (NIF). It builds on the successes of its predecessor, the Gated Diffraction Development Diagnostic (G3D). The FIDDLE was designed to support eight Daedalus version 2 sensors (six more hCMOS sensors than any other hCMOS-based diagnostic in NIF to date) and an integrated streak camera. We will review the electrical requirements, design, and performance of the electrical subsystems that were created to support this large number of cameras in the FIDDLE. The analysis of the data that the FIDDLE is intended to collect relies heavily on the accurate and well-understood timing of each sensor. We report camera-to-camera timing jitter of less than 100 ps rms and sensor integration times of 2.2 ns FWHM in 2-2 timing mode. Additionally, diffraction experiments on the NIF produce electric fields (EMI) on the order of 1 kV/m, which have been observed to negatively impact the performance of some electrical components of the FIDDLE. We report on the results of testing hCMOS camera electronics in a similar EMI environment generated in an offline lab. In addition, we also summarize the use of a novel approach to using a vector network analyzer as an EMI leak detector to understand and reduce the negative impacts of EMI on the FIDDLE.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

TEAMER - Acoustic Particle Velocity Measurements - CRADA 601 (Abstract)

With relatively few deployments of tidal turbines, the extent and effect of underwater sounds generated from these turbines is not well understood. The University of Washington (UW) is deploying a cross-flow turbine system, the Turbine Lander, in the entrance channel to Sequim Bay. The deployment of this system provides an opportunity to understand the noise radiated by the turbine and its sources. There are three hypothesized sound sources associated with operation of the turbine: 1) a continuous tone associated with energized power electronics; 2) sound associated with the generator when the turbine is rotating; and 3) sound associated with the bearing pack that supports the rotor. PNNL is collaborating with UW and Integral Consulting Inc. (Integral) to simultaneously measure sound sources using three different devices. The NoiseSpotter®, an acoustic sensor system designed by Integral, measures acoustic pressure and a three-dimensional particle velocity vector. The NoiseSpotter, along with a commercial-off-the-shelf acoustic particle motion and pressure sensor (M20-105, Geospectrum Technologies Inc.) owned by PNNL will be deployed on the seabed approximately 50-100 m from the Turbine Lander. UW will concurrently deploy Drifting Acoustic Instrumentation SYstems (DAISYs) to characterize acoustic pressure near the Turbine Lander and localize sounds using a Time Delay of Arrival (TDOA) algorithm. Integral, UW, and PNNL will collaborate on data analysis and interpretation, with the intention of jointly authoring an archival paper on the results. The noise generated from the Turbine Lander is not expected to be significant, yet this experiment will help to evaluate the efficacy of combining technologies to characterize noise and provide insights for approaches to consider for future turbine deployments at other locations.

16 TIDAL AND WAVE POWER↗

DOE OSTI2024

Atomic Magnetometry Using a Metasurface Polarizing Beamsplitter in Silicon-on-Sapphire

Here, we demonstrate atomic magnetometry using a metasurface polarizing beamsplitter fabricated on a silicon-on-sapphire (SOS) platform. The metasurface splits a beam that is near-resonant with the rubidium atoms (795 nm) into orthogonal linear polarizations, enabling the measurement of magnetically sensitive circular birefringence in rubidium vapor through balanced polarimetry. We incorporated the metasurface into an atomic magnetometer based on nonlinear magneto-optical rotation and measured subnanotesla sensitivity, which is limited by low-frequency technical noise and transmission loss through the metasurface. To our knowledge, this work represents the first demonstration of SOS nanophotonics for atom-based sensing and paves the way for highly integrated, miniaturized atomic sensors with enhanced sensitivity and portability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Virtual sensing-enabled digital twin framework for real-time monitoring of nuclear systems leveraging deep neural operators

Abstract Real-time monitoring is a foundation of nuclear digital twin technology, crucial for detecting material degradation and maintaining nuclear system integrity. Traditional physical sensor systems face limitations, particularly in measuring critical parameters in hard-to-reach or harsh environments, often resulting in incomplete data coverage. Machine learning-driven virtual sensors offer a transformative solution by complementing physical sensors in monitoring critical degradation indicators. This paper introduces the use of Deep Operator Networks (DeepONet) to predict key thermal-hydraulic parameters in the hot leg of pressurized water reactor. DeepONet acts as a virtual sensor, mapping operational inputs to spatially distributed system behaviors without requiring frequent retraining. Our results show that DeepONet achieves low mean squared and Relative L2 error, making predictions 1400 times faster than traditional CFD simulations . These characteristics enable DeepONet to function as a real-time virtual sensor, synchronizing with the physical system to track degradation conditions and provide insights within the digital twin framework for nuclear systems.

Hossain, Raisa↗

DOE OSTI2020

Intrinsic thermal interfacial resistance measurement in bonded metal–polymer foils

Heat conduction through bonded metal–polymer interfaces often limits the overall heat transfer in electronic packaging, batteries, and heat recovery systems. To design the thermal circuit in such systems, it is essential to measure the thermal interfacial resistance (TIR) across ~1 µm to 100 µm junctions. Previously reported TIR of metal–polymer junctions utilize ASTM E1530-based two-block systems that measure the TIR by applying pressure across the interface through external heating and cooling blocks. Here, we report a novel modification of the ASTM-E1530 technique that employs integrated heaters and sensors to provide an intrinsic TIR measurement of an adhesively bonded metal–polymer junction. We design the measurement technique using finite element simulations to either passively suppress or actively compensate the lateral heat diffusion through the polymer, which can minimize the systematic error to ≲5%. Through proof-of-concept experiments, we report the TIR of metal–polymer interfaces made from DuPont’s Pyralux double-side copper-clad laminates, commonly used in flexible printed circuit boards. Our TIR measurement errors are <10%. We highlight additional sources of errors due to non-idealities in the experiment and discuss possible ways to overcome them. Our measurement technique is also applicable to interfaces that are electrically insulating such as adhesively joined metal–metal junctions and sputter-coated or welded metal–polymer junctions. Altogether, the technique is capable of measuring TIR ≳10 –5 m 2 KW –1 in bonded metal–polymer foils and can be tailored for in situ measurements in flexible electronics, circuit packaging, and other hybrid metal–polymer systems.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Setups for eliminating static charge of the ATLAS18 strip sensors

Abstract Construction of the new all-silicon Inner Tracker (ITk), developed by the ATLAS collaboration to beable to track charged particles produced at the High-Luminosity LHC, started in 2020 and is expected tocontinue till 2028. The ITk detector will include 18,000 highly segmented and radiation hard n+-in-psilicon strip sensors (ATLAS18), which are being manufactured by Hamamatsu Photonics. Mechanical and electrical characteristics of produced sensors are measured upon their delivery at several institutes participating in a complex Quality Control (QC) program. The QC tests performed on each individual sensor check the overall integrity and quality of the sensor.During the QC testing of ATLAS18 strip sensors, an increased number of sensors thatfailed the electrical tests was observed. In particular, IV measurements indicated an early breakdown,while large areas containing several tens or hundreds of neighbouring strips with low interstrip isolationwere identified by the Full strip tests, and leakage current instabilities were measured in a long-term leakage current stability setup. Moreover, a high surface electrostatic charge reaching a level of several hundreds of volts per inch was measured on a large number of sensors and on the plastic sheets, whichmechanically protect these sensors in their paper envelopes. Accumulated data indicates a clearcorrelation between observed electrical failures and the sensor charge-up.To mitigate the above-described issues, the QC testing sites significantly modified the sensor handlingprocedures and introduced sensor recovery techniques based on irradiation of the sensor surface with UVlight or application of intensive flows of ionized gas. In this presentation, we will describe the setupsimplemented by the QC testing sites to treat silicon strip sensors affected by static charge andevaluate the effectiveness of these setups in terms of improvement of the sensor performance.

Instruments & Instrumentation↗

DOE OSTI2025

Fine-Grained Application Energy and Power Measurements on the Frontier Exascale System

The increasing complexity and power/energy demands of heterogeneous exascale systems, such as the Frontier supercomputer, present significant challenges for measuring and optimizing power consumption in applications. Current tools either lack the resolution to capture fine-grained power and energy measurements, fail to validate in-band measurements against out-of-band power sensors, or cannot integrate this information with application performance events in a scalable manner. This paper introduces a novel open-source performance toolkit that integrates extended PAPI components with Score-P plugins to enable in-band, fine-grained power and energy measurements, while also supporting validation using power meter measurements for both CPUs and GPUs. One key contribution is the ability to perform millisecond-level power and energy measurements for AMD MI250X GPUs, mapping them to application performance events within a single trace and measurement system that scales. Our toolkit combines coarse-grained measurements from cray_pm counters with high-resolution metrics from rocm_smi and RAPL, converting GPU instantaneous accumulated energy into power to capture both transient and steady-state power behavior, a capability often missed by out-of-band and monitoring tools. By mapping these metrics to specific application regions, developers can identify energy hotspots, address inefficiencies in GPU kernel execution, and validate in-band measurements against external measurements. We demonstrate the effectiveness of this approach through case studies using benchmarks such as GPU rocblas_sgemm, BLIS c_blas_dgemm, and rocHPL, highlighting the variability of the measurements and the impact of transient power spikes on kernel-level efficiency.

Hernandez Mendoza, Oscar [ORNL] (ORCID:00000002538↗

DOE OSTI2021

Science Breakthroughs 2030. Final report

Agriculture is a fundamental societal activity, characterized by many different landscapes, crops, markets, and participants. Food, agricultural, and biofuels products are central to the daily life of all citizens, though most do not recognize the fragility of the environment that brings forth this abundance. As is noted in the 2012 report from the President's Council of Advisors on Science and Technology, Agricultural Preparedness and the United States Agricultural Research Enterprise (PCAST, 2012) the food and agricultural system faces constant challenges in: Managing new pests, pathogens, and invasive plants. Increasing the efficiency of water use. Growing food in a changing climate. Reducing the environmental footprint of agriculture. Managing the production of bioenergy. Producing safe and nutritious food. Assisting with global food security and maintaining abundant yields. Science Breakthroughs 2030 was organized to identify the most compelling research directions in food and agriculture, in particular those empowered by the application of insights and tools from disciplines of science and engineering not typically associated with food and agricultural research. A committee appointed by the Chairman of the National Research Council explored ideas for research directions with input from the scientific community, with the objective of producing a report describing ambitious and achievable scientific pathways to address major problems and create new opportunities in food and agriculture. Following numerous meetings, a jamboree, and town hall, the appointed committee prepared a report that has subsequently become a reference for federal agencies supporting research in the food and agricultural space. It highlights five key areas for research investment with broad application across food and agriculture: integrated systems research; sensor development; data mining and information sciences, genomics; and the microbiome.

09 BIOMASS FUELS↗

DOE OSTI2022

A Review: PFAS Adsorption, Sensing, and Remediation with Engineered Nanoporous Materials

Per- and polyfluoroalkyl substances (PFAS) are among the most abundant environmental contaminant species. They are widespread due to uncontrolled industrial and commercial use and have been linked to health risks such as cancer. With rising global concerns about the public health effects of PFAS, there is an incentive to develop strategies for reliable monitoring and effective PFAS removal, particularly in drinking water. Traditional PFAS sensing techniques are inefficient due to long measurement times, high labor input, high costs, and limitations to ex situ analysis. Current commercially available sorbents for PFAS removal generally lack the ability to capture PFAS components rapidly and quantitatively. Furthermore, existing sorbents are notably inefficient in removing the more toxic, smaller PFAS chemical chains. Large-scale applications of these methods tend to be costly and resource-intensive. Pacific Northwest National Laboratory has developed unique strategies for PFAS sensing and removal with capture probe technology that has an affinity for fluorocarbons, including PFAS. For both sensing and removal, the customizable capture probes can target specific PFAS compounds since they used a metal-organic framework (MOF)-based technology that can be fine-tuned and molecularly tailored. This tailoring of the materials enables high PFAS sensitivity, selectivity, and faster uptake. PNNL’s capture probe materials have been developed into a sensing technique based on the interactions of the capture probes with PFAS at the molecular level and further transduced that to a quantifiable electrochemical response. The materials have been integrated into a sensor platform developed by New Jersey Institute of Technology (NJIT). Tunable capture probes with a range of detection sensitivities allow for faster and more sensitive PFAS detection limits as low as what appears to be 0.5 ng/L (compared to the U.S. Environmental Protection Agency health advisory level of 70 ng/L). Customization of the capture probe results in improved sorption capacities (fast kinetics and high capacities) compared to commercial granular activated carbons. This research applied various experimental and modeling tools to improve understanding the molecular level interactions between the sorbents towards PFAS adsorption properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Design, Build, and Initial Testing of a Portable Methane Measurement Platform

The quantification of methane concentrations in air is essential for the quantification of methane emissions, which in turn is necessary to determine absolute emissions and the efficacy of emission mitigation strategies. These are essential if countries are to meet climate goals. Large-scale deployment of methane analyzers across millions of emission sites is prohibitively expensive, and lower-cost instrumentation has been recently developed as an alternative. Currently, it is unclear how cheaper instrumentation will affect measurement resolution or accuracy. To test this, the Wireless Autonomous Transportable Methane Emission Reporting System (WATCH 4 ERS) has been developed, comprising four commercially available sensing technologies: metal oxide (MOx,), Non-dispersion Infrared (NDIR), integrated infrared (INIR), and tunable diode laser absorption spectrometer (TDLAS). WATCHERS is the accumulated knowledge of several long-term methane measurement projects at Colorado State University’s Methane Emission Technology Evaluation Center (METEC), and this study describes the integration of these sensors into a single unit and reports initial instrument response to calibration procedures and controlled release experiments. Specifically, this paper aims to describe the development of the WATCH 4 ERS unit, report initial sensor responses, and describe future research goals. Meanwhile, future work will use data gathered by multiple WATCH 4 ERS units to 1. better understand the cost–benefit balance of methane sensors, and 2. identify how decreasing instrumentation costs could increase deployment coverage and therefore inform large-scale methane monitoring strategies. Both calibration and response experiments indicate the INIR has little practical use for measuring methane concentrations less than 500 ppm. The MOx sensor is shown to have a logarithmic response to methane concentration change between background and 600 ppm but it is strongly suggested that passively sampling MOx sensors cannot respond fast enough to report concentrations that change in a sub-minute time frame. The NDIR sensor reported a linear change to methane concentration between background and 600 ppm, although there was a noticeable lag in reporting changing concentration, especially at higher values, and individual peaks could be observed throughout the experiment even when the plumes were released 5 s apart. The TDLAS sensor reported all changes in concentration but remains prohibitively expensive. Our findings suggest that each sensor technology could be optimized by either operational design or deployment location to quantify methane emissions. The WATCH4ERS units will be deployed in real-world environments to investigate the utility of each in the future.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

CONTROL AND DATA ACQUISITION IN A CYBER-PHYSICAL MIDSTREAM TESTBED

This thesis presents the development of a laboratory-scale cyber–physical midstream pipeline testbed designed to address this gap and support research in industrial control systems security. The platform integrates pumps, valves, sensors, programmable logic controllers (PLCs), and a human–machine interface (HMI) to emulate the monitoring and control architecture of real pipeline operations. The physical process is implemented as a closed-loop liquid circulation system designed to replicate flow behavior characteristic of midstream pipeline infrastructure. The testbed enables real-time data acquisition of key process variables, including flow rate and pressure facilitating the generation of datasets representative of normal pipeline operation. A threat model encompassing common ICS attack vectors was developed, including sensor spoofing, command injection, false data injection, denial-of-service attacks, and relay manipulation. Multiple attack scenarios were implemented and evaluated to demonstrate how cyber intrusions targeting sensors, actuators, networks, and software propagate into measurable physical consequences in pipeline flow and pressure. The developed platform serves as a practical, cost-effective environment for experimentation, education, and future cybersecurity research in midstream pipeline systems.

42 ENGINEERING↗