Moazzam Shamsi, global solutions architect for connectivity, explains how modern communication technologies and innovative connectivity solutions are helping to meet the demand for more data from more sources.
The automation industry is being driven to expand its connectivity options due to the increase in demand for more data from more sources. This requires communications solutions that balance speed, power consumption, latency, ease of integration and security, all whilst maintaining data fidelity. The nature of data from the field and plant floor is changing and robust connectivity is essential for effective management of volumes and types of data. This unlocks diagnostic and application potential of field devices, improving line of sight to the asset whilst providing greater context for plant decision-makers who could be located anywhere in the plant or enterprise. To meet this challenge, emerging and enhanced communication technologies such as Ethernet-APL™ (Advanced Physical Layer), wireless and cellular networks are facilitating the seamless transfer of contextualized, high-fidelity data from all parts of the operation to the people and systems that need it, wherever they are located. This is creating the possibility for new applications, and valuable operational insights provided by powerful edge- and cloud-based software.
Wireless field networks are helping organizations to deploy pervasive sensing technologies at a lower cost than wired installations, often in applications previously inaccessible by wired methods. Infrastructure technology enhancements are enabling more dense applications and longer-range transmission. This includes adding further traditional process measurement points and eliminating other operational blind spots. Implementing new applications such as corrosion, valve and vibration monitoring and gas leak detection supports the reliability, safety and sustainability domains.
Cellular networks traditionally only used for backhauling applications are becoming faster and more robust, making them suitable for a broader range of industrial applications. Using public cellular networks with low-cost data rates, inexpensive sensors can be deployed in remote monitoring applications and data sent directly to the cloud for centralized analysis, enabling new ‘fleet management’ services. New business and service capabilities are emerging; for example, suppliers can monitor inventory levels and the condition of liquids in remote and mobile storage tanks, helping to improve supply chain efficiency and service levels. Alternatively, greater visibility to the health of pipeline infrastructure and equipment can minimize manual inspections and improve environmental and safety performance. Companies that are tracking their carbon footprint will have new alternatives to measure energy consumption on a global scale.
Ethernet-APL aims to bring Ethernet communications to field instrumentation, including those in hazardous areas. Deploying high-speed Ethernet in the field creates opportunities for new sensor types requiring greater bandwidth and accelerates device configuration and maintenance tasks. Ethernet-APL has been designed to support the transfer of large volumes of data such as analytical data and cameras being used as sensors. Many existing data-rich devices such as digital valve controllers and Coriolis flow meters will also benefit from the faster speeds. Users familiar with PROFIBUS are beginning to deploy PROFINET over Ethernet-APL, while HART® and WirelessHART® users will likely look to adopt HART-IP because of new security features and their familiarity with HART engineering tools.
Connectivity critical to modern architectures
Facilitating easier integration of these emerging communication platforms requires innovative connectivity solutions. Extensible and scalable architectures and the available infrastructure must help to reduce the cost and complexity of implementation, provide the necessary levels of security, maintain or improve reliability and performance, and deliver the flexibility required to support more applications. Innovative connectivity solutions simplify integration, reduce installation costs and facilitate the addition of new measurement points quickly. For example:
Enhanced WirelessHART gateways expand the number of connectable devices without the cost of additional gateways. This enables new applications to be implemented while leveraging existing infrastructure.
Smart antennas that enable remote mounting from the gateway, including hazardous areas, simplify the implementation of new applications such as gas leak detection.
CHARacterization Modules (CHARMs) allow field wiring to be terminated anywhere, reducing the complexity of connecting new devices and smart sensors.
DeltaV™ CHARMs supporting Ethernet-APL applications will ultimately simplify the integration of Ethernet-APL devices and networks into existing automation architectures, reducing project costs and complexity.
DeltaV PK Controller integrates Ethernet-APL through communications protocols including PROFINET, Modbus TCP, OPC UA and Ethernet/IP, allowing users to mix and match device types in one control strategy. When combined with Ethernet-APL switches, the PK Controller accelerates the adoption of high-speed devices in process environments.
DeltaV IO.Connect software allows I/O to be preserved during control system modernization, enabling incremental updates without downtime. This flexibility reduces schedules by up to 90% and overall capital costs by up to 40%, with future I/O changes falling into operational expenditure.
Network security
The increased connectivity and open nature of the networking required to transmit this wealth of data to the appropriate people and systems introduces new security requirements to reduce risks and prevent vulnerabilities. Cybersecurity is therefore a critical concern. To help alleviate this concern, automation companies such as Emerson are using zero-trust principles to enhance security. Zero trust assumes that the network has been or will be compromised and that no user or asset can be implicitly trusted. Rather than engineer security retrospectively, automation software and applications have a zero-trust principles designed in.
Although end users want to immediately reap the benefits of powerful sensors and other field devices enabled by new high-speed communications, adoption within many existing plants is likely to be a gradual process. Careful integration of old and new communications will be essential to ensure they operate together with confidence. Emerson’s expertise, proven technologies and processes can help deliver maximum value at the lowest possible risk.
Learn all about Boundless AutomationSM in “Innovations in Automation”.
