Binary Image-Based Intrusion Detection for Operational Technology Networks: Extending the SPHBI Methodology from IoT to Modbus TCP

Abstract: This paper extends the Single Packet Header Binary Image (SPHBI) intrusion detection methodology from IoT to Modbus TCP, evaluating five approaches spanning a gradient of protocol depth on the CIC Modbus 2023 dataset (11.4 million packets, eight detectable attack types). TCP/IP headers alone achieve only 51.8% binary accuracy, confirming that header-level heterogeneity exploited in IoT traffic is absent in uniform SCADA environments. Adding eight bytes of application-layer information improves binary accuracy to 98.1% with just 63 parameters, directly relevant to per-packet classification on resource-constrained OT edge devices. The best-performing approach achieves 94.4% +/- 2.2pp multiclass accuracy across nine classes (95% CI [92.9%, 95.9%], 10 seeds) with 56,873 parameters, roughly 430 times fewer than comparable ResNet50-based approaches. Per-class recall analysis shows seven of eight detectable attack types identified with recall above 94%, while replay attacks remain structurally undetectable by any single-packet method.