Brad S. Carlberg, P.E. Jim McConahay Ethernet I/O Brad S. Carlberg, P.E. Jim McConahay

Co-Presenter: Brad S. Carlberg Brad S. Carlberg, P.E. is a Consulting Engineer in Richland, Washington. He is a Registered Professional Control Systems Engineer in the states of Alabama and Washington with over twenty-five years experience in industrial automation and Process Control Engineering. Specifically he has experience with Distributed Control Systems and Programmable Logic Controllers combining extensive experience with both Hardware and Software Design, Programming, Implementation and Startup. Brad received his Bachelor of Science in Mechanical Engineering from Washington State University in Pullman, Washington in 1984. Brad is a Senior Member of ISA who has been a conference program committee member since 1997. BSC Engineering

Co-Presenter: Jim McConahay Jim McConahay, P.E. is an ISA member and holds a BSEE and MBA from Cal Poly University, Pomona California. Has 30+ years design and installation experience in Production and Automation equipment. Jim is a Sr. Field Application Engineer for Moore Industries-International, Inc. concentrating on process control instruments, SCADA, SIS (Safety Instrumented Systems), fieldbus, data concentrators and communications links.

Agenda Agenda Physical Layers of Ethernet Protocol Medley Migration From Cabinet to the Plant Floor Enhanced Features of Ethernet I/O Architecture Considerations Security Examples of Ethernet Communications

OSI Model OSI (Open Systems Interconnect) Model 7 6 5 4 3 2 1 Application Presentation Session Transport Network Data Link Physical 6 “Ethernet” IEEE 802.3x only applies here 5 4 3 2 UTP, STP, Fiber, Coax, etc. 10/100/1000/10G speeds 1

What “language” are you talking?? Protocol OSI Model Protocols run on top of Ethernet 7 MODBUS, OPC, HTTP, Etc. What “language” are you talking?? Protocol 6 Presentation 5 Session Addressing and Handshaking Protocols 4 TCP 3 IP Ethernet 2 UTP, STP, Fiber, Coax, etc. Ethernet 1

MODBUS/TCP Ethernet/IP FF HSE CIP Open Standards Ensure that your Ethernet I/O supports open standards for connectivity: OPC, MODBUS/TCP, Ethernet/IP, HTTP, HSE etc. OPC HTTP MODBUS/TCP Ethernet/IP FF HSE CIP HMI, PC, DCS, PLC

Ethernet vs. Twisted Pair Communications Media Ethernet vs. Twisted Pair Speed Multiple Protocols over same cable Plant wiring infrastructure Non-Proprietary hardware available (lower cost) Switch advancements have improved determinism Power over Ethernet HMI, PC, DCS, PLC

What if the protocols don’t match? Protocol Gateway What if the protocols don’t match? Is there a solution? Gateway (Protocol Converter) Ethernet to Ethernet Ethernet to Serial Wireless to Serial/Ethernet HMI, PC, DCS,PLC

Protocol Converters and Gateways Protocol Gateway Protocol Converters and Gateways The term “gateway” has many meanings. One common definition is a protocol converter. Sometimes host and legacy systems can only communicate via one particular protocol. Or, instruments may support one protocol but not the one that the host system supports. Gateways can be very effective solutions that connect these two devices. Since Ethernet is “open” gateways are becoming more and more common. Sometimes people refer to “drivers” as gateways. A driver is essentially a protocol or language translator.

Simplified Gateway Example HART Data Map MODBUS Data Map Gateway Internal Mem. MODBUS Slave mapping HART Master 68.6 68.6 MODBUS Master gets new data HART Device is polled MODBUS Data Map Internal Mapping Takes Place

Moving from the Cabinet to the Field • Temperature Considerations 55C vs. 85C operating Temp’s. • Channel-to-channel, and input-to-output signal isolation eliminates unpredictable ground loops • RFI/EMI protection protects against plant noise • Accuracy, long term stability, and Input/output resolution of transmitters

Common I/O Multiplexer Isolated Channels Signal Inputs/Outputs A/D Converter mP Typical I/O Card Design -single point of failure -isolation Common I/O Multiplexer Signal Input Signal Input Signal Input Signal Input Transmitter Like Design -isolation -flexibility of input type A/D A/D A/D A/D mP mP mP mP Enhanced I/O Design

Isolated Channels Plant Floor “Industrialized” Ethernet I/O Power and Flexibility of PLC’s Resolution, Accuracy, and Spec’s of Field Transmitters (Cabinet Mounted) (Field Mounted) Plant Floor “Industrialized” Ethernet I/O

“Hardened” Plant Floor Switches High Temp -40 to 85C vs. commercial ~45C High Vibration Tolerance RFI/EMI Rejection Surge Protection Dual Power Supply Options for UPS Systems

Switch Features for the Plant Floor QoS (Quality of Service) -Packet Prioritization SNMP (Simple Network Management Protocol) SMTP Client (Emails about network warnings/breaks) MAC Layer Filtering IP Layer Filtering

Programming should be easy and intuitive; i.e. web based Set-Ups Programming should be easy and intuitive; i.e. web based

Do you need more than I/O gathering? Ethernet I/O systems are smarter and more powerful than ever. Many times PLC’s are used to perform simple control, math and logic functions. Questions to ask your Ethernet I/O vendor Does your Ethernet I/O have the ability to perform control and math? Is the control programming language proprietary? …

Is the programming language Compliant Language Is the programming language 61131-3 compliant? Function Block Diagram (FBD) Example

Know your design needs before choosing your Ethernet I/O system Topology Know your design needs before choosing your Ethernet I/O system Peer-to-Host—Star Topology; Bus Topology Peer-to-Peer Hybrid—Peer-to-peer and Peer-to-Host Wireless/Fiber/Copper

Dispersed Monitoring & Control Devices Peer-to-Host System DCS, PLC or PC with HMI/SCADA (with NET Concentrator System OPC Server) Ethernet I/O System Ethernet I/O System Additional NET Concentrator System Stations or Uplink to Other Hubs or Switches Ethernet I/O System Ethernet Switch or Hub Ethernet I/O System Dispersed Monitoring & Control Devices Analog Direct Valve On/Off Transmitter Temperature Positioners Contact Closure Relay Devices Sensors Temperature Pressure Level RTD Thermocouple On/Off Proportional

(cost savings with traditional I/O cards) Ethernet/Fiber Network Peer-to-Peer System (cost savings with traditional I/O cards) Ethernet/Fiber Network PAIR 1 Ethernet I/O System Ethernet I/O System Ethernet I/O System PAIR 2 PAIR 3 Ethernet I/O System Ethernet I/O System

Add Wireless… Wireless Peer-to-Peer/Host Systems 900Mhz or 2.4Ghz – License Free or Licensed Ethernet I/O System PAIR 1 PAIR 2 Ethernet I/O System Ethernet I/O System

Security Concerns Firewalls NAT Routers Virus Protection Physical Security (personnel and Internet Connection) “Line speed” packet encryption systems

Network Architecture Considerations- “Connected” Networking Network Architecture Considerations- “Connected” VPN Outside Internet Connections Typical Front Office Network Most Convenient but Potentially Vulnerable Router/Firewall Process Control Network

Network Architecture Considerations- “Disconnected” Networking Network Architecture Considerations- “Disconnected” VPN Front Office Network Outside Internet Connections Typical Safer but Inconvenient No Physical Connection Process Control Network

Case Study #1 One communication loop, multiple bus Problem: PAC – Programmable Automation Controller Ethernet card in PAC backplane – Ethernet TCP/IP HMI Ethernet IP and Ethernet TCP/IP Flow, valves, level sensors / FF FF FIM; H1 to HSE link – Ethernet IP (not TCP/IP) Ethernet protocol conflict between FIM and PAC

Case Study #1 One communication loop, two bus Solution: Add MODBUS TCP to Ethernet IP Protocol Converter Two way FF protocol conversion with PAC 28

Case Study #1 One communication loop, two bus Optimized equipment for each part of the system Used protocol converter to make compatible Lowest cost item in the system Far less cost than compromise performance of a single vendor solution

Case Study #2 Remote ESD for Oil Platform in Gulf Problem: Maintenance Boat and Oil Rig Platform pipeline repairs Repairs involve heavy equipment above seafloor pipelines If accident event, need system to shut down Production ESD (Emergency Shutdown Device) Automatic Reliable Two-way verification of link Off shore Portable, distance >100 km Beyond radio links

Case Study #2 Remote ESD for Oil Platform in Gulf Considerations: No hard line communication links No ESD = No Drilling ($$$) Is existing Emails, Internet and VoIP to shore facilities Satellite link is reliable on platform Satellite link is reliable on Maintenance ship Maintenance ship is very mobile Easy installation Transferrable to new ship Simple, intuitive to operate

Case Study #2 Remote ESD for Oil Platform in Gulf Solution: Data concentrator on Maintenance boat Ethernet Communications module Discrete input/output module Packaging with switch plus display lamp tree Data concentrator of Oil Platform Packaging with switch, klaxon, plus display lamp tree Connection to control panel Expansion Add SCADA to ESD at negligible cost

Case Study #2 Remote ESD for Oil Platform in Gulf Things at the surface can drop onto sea floor pipelines

Case Study #2 Remote ESD for Oil Platform in Gulf Success Operational upon initial installation, continuous operation Simple to operate, intuitive. Reliable. Now hard-wired to control panel circuits. Satellite signal limited by extreme weather. Expansion Can add I/O modules for telemetry on both ends of links; negligible cost.

Case Study #3 Expansion of 4-20mA loops Problem: Expansion, low budget, needs more 4-20mA channels Requires more 4-20mA channels now No budget to replace existing 4-20mA lengthy cable run Will require still more channels later Discrete contact requirement arising Ethernet cable upgrade Available in the future, not now Does not want to waste investment in temporary data concentrator when Ethernet cable becomes available in the future

Case Study #3 Expansion of 4-20 loops Solution Data Concentrator MODBUS RTU communications at module each site AIM each output; AOM each output DIM each discrete input; ROM each discrete output Increase number of I/O modules, as desired Increase pairs of data concentrators Use existing twisted pair cable Use one twisted pair to carry ‘all’ channels between data concentrators

Case Study #3 Expansion of 4-20mA loops Data Concentrator on a Peer-to-Peer network Originally MODBUS Communications Link Currently Ethernet Communications Link

Case Study #3 Expansion of 4-20mA loops Success Use data concentrators to collect all 4-20mA loops and convert to digital communications. Increased number of analog channels, and also easily adds discrete channels Only one twisted pair required Recreate signal at distant site with no degrading of analog signal (since communication is digital) Low cost Ethernet upgrade Swap only the MIM for an EIM communications module All other modules are same

Case Study #4 Wireless HART, MODBUS RTU & TCP/IP Problem: Multiple tasks, need to optimize Tank farm, Wireless HART; multiple sensors, cable expenses Closed loop room; add sensors, valves plus data concentrator Host control room—long distance communication link Different communications media and protocol Wireless Hart; radio Data concentrator; analog/discrete I/O; programming MODBUS Need protocol converters Wireless Hart to MODBUS RTU slave MODBUS RTU master; control loop; MODBUS TCP slave

Case Study #4 Wireless HART, MODBUS RTU & TCP/IP

“Our View” - Market Trend with Ethernet Summary “Our View” - Market Trend with Ethernet MODBUS/TCP - MODBUS packets encapsulated in TCP/IP frames Reason: Everyone knows MODBUS, open protocol, and already supported worldwide Ethernet/IP - “Industrial Protocol”, Rockwell released to ODVA (Open DeviceNet Vendor Association) Reason: Open, supports common publisher/subscriber method of comm., section of protocol already supported in open DeviceNet. Uses CIP (Common Industrial Protocol) for real time control. OPC -OLE for Process Control. Uses Microsoft’s COM/DCOM/ .NET standards for open comm. Reason: OPC can run over any physical medium and is an open, free of charge protocol that both hardware vendors and software vendors have access to. Many supported development tools. Strong backing by OPC Foundation.

Market Trend with Ethernet Cont’d Summary Market Trend with Ethernet Cont’d 4. HSE - High Speed Ethernet Foundation Fieldbus protocol over Ethernet. Reason: Open protocol, and large organized support base by Foundation Fieldbus vendors and FF org. Profinet - Profibus Trade Organization’s answer to open communications. It is NOT Profibus over Ethernet!!! Reason: Strong backing by PTO. Can use 802.3 layer but not restricted to this layer. Can run over modems, WAN’s, VPN’s, as long as it uses TCP/IP addressing. CIP - Common Industrial Protocol is being promoted by ODVA (Open Device Vendors Association). Uses a Producer consumer network philosophy for real time control applications.

Questions? BSC Engineering Thank You!