Optimization of Process Integration:
Using EtherNet/IP for Integration of Field
Devices with a Process Automation System

October 14, 2015 2:00 PM – 3:45 PM

Welcome, Background, and History

Shannon R. Foos, P.E.
ODVA Strategic Marketing Requirements Team, Leader
SRFoos@ra.Rockwell.com

Terry Minns
ODVA Strategic Marketing Requirements Team
Terry.Minns@Schneider-electric.com

Marketing Track© 2015 ODVA, Inc.

2015 Industry Conference & 17th Annual Meeting
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2

Welcome
2:00 – 2:10 Background and History of Optimization of Process Integration (OPI)
2:10 – 2:15 Reference Architecture for OPI
2:15 – 2:30 Developments by ODVA’s Special Interest Group for EtherNet/IP in the Process
Industries
2:30 - 3:30 Adjacent Technical Developments Important to the Realization of OPI in Field Devices

A New Perspective on Integration of Field Devices: Using the FDT Standard with EtherNet/IP
Physical Layer – Overview and Demonstration of New Physical Layer Concepts for Industrial
Ethernet and EtherNet/IP in Process Field Devices
3:30 – 3:45 Panel Session: Industry Perspectives on EtherNet/IP for the Process Industries

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The Process Initiative
SMRt Participants

White Paper

Next steps: 12-18
months• Finalizing EtherNet/IP
Input Assembly
structure including
device diagnostics• Finalizing HART
mapping on
EtherNet/IP• Define PoE
adaptation for
EtherNet/IP• Additional
EtherNet/IP work
plan topics

Work Plan

Cisco Systems
René Pluis
Endress+Hauser
Olivier Wolff
Rockwell Automation*Shannon Foos*
Schneider Electric
Terry Minns
ODVA Katherine Voss

2010

2011

2012

2013

2014

2015

SIG - 19 members, 10 different vendors
Active Participants:
Cisco Systems (René Pluis)
Rosemount (Eric Rotvold)
Endress+Hauser (*Mirko Brcic*, Martin Hönicke)
Krohne (Christian Brehm, Christoph Spiegel) 2015 Industry Conference & 17th Annual Meeting
Industry Conference - Marketing Track
RockwellSchumaker)© 2015ODVA,Automation
Inc. All rights(Carlreserved.
www.odva.org
Schneider Electric (Stephane Hernu, Terry Minns, Mark Rossi)

2016

FutureAchievements• Defined EtherNet/IP Reference
Architecture for Process Industries• Draft of EtherNet/IP Input Assembly
structure including Process Diagnostic• Draft of HART mapping on EtherNet/IP
4

Reference Architecture
Olivier Wolff
ODVA Strategic Marketing Requirements Team
Olivier.Wolff@solutions.endress.com

Rene Pluis
ODVA Strategic Marketing Requirements Team
RePluis@Cisco.com

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Logical Network Reference ArchitectureStandard Ethernet
Industrial Ethernet (e.g. EtherNet/IP)
Fieldbus (e.g. PROFIBUS, FOUNDATION Fieldbus)
4-20mA (and HART)
Wireless (e.g. WirelessHART, ISA100)

Internet / WAN

Intranet

Network services

L4

Patch Management
Terminal Services
AV Servers

Asset Management Station,
Historian, etc.

Operator Station

DMZ

L3½

Control Domain

L3

Enterprise switch

Historian
Network services

Industrial Firewall

L5

ERP
Web servers

Enterprise Firewall

Engineering Station

Enterprise Zone

MES

L2½
Industrial Switch

Industrial Switch

Control Network

Safety Zone
Fieldbus
enableddevices

Wireless
enableddevices

Remote I/O

L2

L1

Fieldbus Gateway

L0

EtherNet/IP enabled devices
General Session© 2015 ODVA, Inc.

2015 Industry Conference & 17th Annual Meeting
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Logical Network Reference ArchitectureStandard Ethernet
Engineering Station
Industrial Ethernet (e.g. EtherNet/IP)
Fieldbus (e.g. PROFIBUS, FOUNDATION Fieldbus)
4-20mA (and HART)
Wireless (e.g. WirelessHART, ISA100)

Operator
StationAsset Management Station,
Historian, etc.

Control Domain

L3

L2½

Historian
Network services

Industrial
SwitchControl Network

L2

Wireless
enableddevices
L1

Safety Zone

EtherNet/IP enabled devices
General Session© 2015 ODVA, Inc.

L0

Fieldbus enabled devices

2015 Industry Conference & 17th Annual Meeting
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The Technical Working Group

Mirko Brcic
ODVA Special Interest Group, Leader
Mirko.Brcic@solutions.endress.com

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8Technical Working Group Overview

New ODVA Special Interest Group (SIG) Formed April 2015
– EtherNet/IP in the Process Industries SIG– Accomplishments and Activities in Progress• Defined Reference Architecture for Process Industries• Draft of Input Assembly structure including Process Diagnostic• Initiated HART mapping on EtherNet/IP• Evaluation of PoE adaptation for EtherNet/IP– Plans for next 12-18 Months
Technical Track© 2015 ODVA, Inc.

2015 Industry Conference & 17th Annual Meeting
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9Accomplishments and Activities in Progress– Defined Reference Architecture for Process Industries• The logical architecture gives an overview of the functionality and segmentation between the several
Purdue levels including Process Networks (FOUNDATION Fieldbus, PROFIBUS, HART and Wireless
Networks)• A physical implementation / realization of the logical architecture can ‘collapse’ Purdue levels in one
physical devices, as long as the associated logical function(s) are realized.
Technical Track© 2015 ODVA, Inc.

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10Accomplishments and Activities in Progress
Draft of Input Assembly structure including Process Diagnostic• Standardized access to process data from EtherNet/IP devices• Self-monitoring and Device Diagnostics according to NAMUR NE107• Proposal was presented at the ODVA EtherNet/IP Roundtable in Raunheim, Germany on
September 30, 2015
1001010110
1011011011
0100101001
00100

Communication Diagnostics
Focus of ODVA Diagnostics Working Group• Quick and effective identification and resolutionof communication problems• Vision: Conduct regular analysis of the network
using network statistics
Technical Track© 2015 ODVA, Inc.

2015 Industry Conference & 17th Annual Meeting
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Self-monitoring and Device Diagnostics
Focus of ODVA Process SIG• Quick and effective identification and resolutionof problems• Vision: Conduct predictive maintenance toreduce downtime and to protect the investment
www.odva.org

11Accomplishments and Activities in Progress– Initiated HART mapping on EtherNet/IP• Update of internal Rockwell object review process• Presentation of technical aspects of object

Remote I/O• Discussion of future work effort

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2015 Industry Conference & 17th Annual Meeting
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12Accomplishments and Activities in Progress
Evaluation of PoE adaptation for EtherNet/IP– First evaluation of PoE adaptation for EtherNet/IP• The current standards for PoE (Power over Ethernet), being IEEE 802.af (formax 15W) and IEE 802.at (for max 30W), can be deployed for Ethernet/IP in
Process environments– Using 4 or 8 wires CAT 5 or above cables• There are several developments to increase the total available power budgets to
60 – 90W or even above as well as integration with IEEE 802.3az (EEE –Energy-Efficient Ethernet)• For those industrial areas which need compliance to ‘intrinsically safe’
standards, the used maximum voltage of PoE needs to be lowered to 12V(instead of the standard used 48V)
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Proposal for next 12-18 months– Follow-up Reference Architecture for Process Industries• Provide implementation examples of the ‘X in the cloud’ or ‘as a service’ developments, e.g.
SCADA implementation in the cloud (either public or private) based on the logical architecture.

– Finalizing EtherNet/IP Input Assembly structure including device diagnostics• Standardized access to process data from EtherNet/IP devices including device diagnostics• Definition of device diagnostics for native EtherNet/IP devices that are compliant with NAMUR
NE-107– Finalizing HART mapping on EtherNet/IP• Standardized CIP object structure to get access to HART

Next ODVAAnnualConference– Define PoE adaptation for EtherNet/IP

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Reference Architecture

October 14, 2015

Logical reference architectureEnterprise Zone L5

Internet / WAN

Standard Ethernet
Industrial Ethernet (e.g. EtherNet/IP)
Fieldbus (e.g. Profibus, Foundation Fieldbus)
4-20mA (and HART)
Wireless (e.g. WirelessHART, ISA100)MES
ERP systems
Web servers

Enterprise Firewall

Engineering Station

L4

Intranet

Network Services

DMZ

Patch Management
Terminal Services
AV Servers

Operator Station

L3½
Asset Management Station,
Historian, etc.

Control Domain

L3

Enterprise switch

Industrial Firewall

Historian
Network Services

L2½
Control Network

Industrial Switch

L2

ICS – Industrial
Control System

Drive

Remote I/O

Fieldbus Gateway

L1

Wireless Gateway

Motor

L0
Safety Zone

Logical reference architecture – functional areas (ISA 95, 88)

L5

Business Process Information Network
Resource Management Production Execution Product Definition Management Detailed Scheduling Configuration Management Production Analysis Production Tracking Production Dispatching

L4

Operations Information Network

L3½
Alarm Management Operator Visibility Equipment Information Collection Operator Control Supervisory Control Recipe Control

L3
L2½

Automation Network
On/Off Control Programmed Control Continuous Control Interlock & Safety Control Phase Control

L2
L1

Discrete & Process Device Communication Networks
Sense Events

Manipulate Equipment

Manipulate Process

Sense Process

Safety Zone

L0

Observations and remarks Logical reference architecture
The logical architecture gives an overview of the functionality and segmentation
between the several Purdue levels.
A physical implementation / realization of the logical architecture can ‘collapse’
Purdue levels in one physical devices, as long as the associated logical
function(s) are realized.
A point of further study will be the incorporation of the ‘X in the cloud’ or ‘as aservice’ developments, e.g. SCADA implementation in the cloud (either public
or private) into this logical architecture.

HART Mapping on CIP

October 14, 2015

Hart Mapping on CIP
HART Mapping on CIP– Update of internal Rockwell object review process– Present technical aspects of object– Discuss future work effort

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PoE in the Process Industries

October 14, 2015

PoE
The current standards for PoE (Power over Ethernet), being IEEE 802.af (for max 15W) and IEE
802.at (for max 30W), can be deployed for Ethernet/IP in Process environments (using 4 or 8
wires CAT 5 or above cables).
There are several developments to increase the total available power budgets to 60 – 90W or
even above as well as integration with IEEE 802.3az (EEE – Energy-Efficient Ethernet).
For those industrial areas which need compliance to ‘intrinsically safe’ standards, the usedmaximum voltage of PoE needs to be lowered to 12V (instead of the standard used 48V).

Technical Track© 2015 ODVA, Inc.

2015 Industry Conference & 17th Annual Meeting
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23

Diagnostics – Status Quo

October 14, 2015

Types of Diagnostic
100101011
010110110
110100101
001001000

Communication Diagnostics
Focus of ODVA Diagnostics
Working Group
Technical Track© 2015 ODVA, Inc.

Self-monitoring and Device
Diagnostics
Focus of ODVA Process SIG

2015 Industry Conference & 17th Annual Meeting
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How diagnostics can be used
Communication Diagnostics– Short term: Quick and effective identification and resolution of communication
problems– Mid term: Conduct regular analysis of the network using network statistics
Self monitoring and Device Diagnostics– Mid-term: Conduct predictive maintenance to reduce downtime and to protect
the investment– Short term: Quick and effective identification and resolution of problems

Technical Track© 2015 ODVA, Inc.

2015 Industry Conference & 17th Annual Meeting
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Device Diagnostics• Modern sensors and actuators are able to do self-monitoring and provide
diagnostic information• In addition to the “Big 12”, this can also be used to prevent downtime• Therefore Device diagnostics were regarded in the Process SIG work plan
Field Device-to-ICS
Integration

Diagnostics

Field Device-toPAM Integration

Seamless, Holistic
Field-to-Enterprise
Communication
Architecture“In particular, the SIG will seek to define device diagnostics for native
EtherNet/IP devices that are compliant with NAMUR NE-107”

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NAMUR• NAMUR is an international association of process automation end
users• NEs are recommendations to help end users and to guide suppliers aswell as industry foundations on future technology and productdevelopment• ~300 active members in ~40 working groups• Members: e.g. Novartis, BASF, Bayer, Evonik, Shell, Clariant, …

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NE107 – “Self-Monitoring and Diagnosis of Field Devices”
Colors and Symbols

Possible sources of error– E.g. electronics, sensor or actuator element, installation, putting into operation, noncompliance with specified operating conditions, connecting to the process

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NE107 – Information Flow

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Accessing Device Diagnostics with EIPGrouping by source (sensor,
electronics,...)

PLC/Tool

Status

Input Assembly(work in progress)

Diagnostic CodeFCSM

NE 107 status signal
channelData(i)

Value

Source of status signal (formultichannel devices)

Status(Padding)?

Engineering unit

NE107-Device
F
C
S
M
Technical Track© 2015 ODVA, Inc.

Data(i+1)…

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Good, bad,(uncertain)?
+simulation flag?
+active flag?
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31Adjacent Technology Developments
Three Use Cases in Optimization of Process Integration:
Field Device to Industrial Control System Integration
Field Device to Plant Asset Management
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Adjacent Technology Developments
Automation Domains
Factory Automation

ODVA

Process Automation• Strong heritage in Factory Automation
applications• Desire to grow in Process Automation• Strong heritage in Process•

Automation applications
Desire to grow in Factory Automation

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A NEW PERSPECTIVE ON INTEGRATION OF
FIELD DEVICES:USING THE FDT STANDARD WITHETHERNET/IP

GLENN B. SCHULZ
MANAGING DIRECTOR
Glenn.Schulz@fdtgroup.org
26/10/2015

34

FDT –Ideal for EtherNet/IP in Process
The FDT standard is the standard for the Process Industry– Commissioning applications– Asset Management applications

Most large HART and FF installations use the FDT standard– Including HART Plant of the Year winners– Written into procurement requirements

Devices Supported
by Certified DTMs

10+ year track record

2015

2014

2013

2012

2011

A large FDT EcoSystem to support vendors

2010– Truly open and free

2009

There is no charge to use the FDT standard

10000
7500
5000
2500
0

2005
2006
2007
2008

– Millions of devices shipped– Tens of thousands of hosts installed– Supported by more than 90 companies– Services, toolkits, consulting
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The FDT Standard
Allows any compliant device to be integrated into a host system (Frame)

Device vendor supplies a DTM (Device Type Manager)– A software representation of the device••••

Configuration (wizards, smart guides, etc.)
Diagnostics
Troubleshooting
Manuals

Host system can “host” any number of DTMs

– Any device type, any vendor,
any mix of industry busesMarketing Track© 2015 ODVA, Inc.

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Key Features of the FDT Standard
Extensible to any new industry bus– Simple “annex” process - e.g. ISA-100 recently added

Transparently tunnel (route) through all networks to talk with end device
Client server or standalone architectures
Layered security model
Latest version fully .NET
– Backward compatible

Recognized world-wide– IEC 62453 / ANSI ISA 103 / China GBT 29618

No licensing or royalties to use the standard
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DTM Examples – Configuration

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DTM Examples –Diagnostics

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Three Types of DTMs
Device DTM
Represents an “end” device e.g. a drive, prox, etc.

Communications DTM
Provide communication channels
which provide the services to accessthe fieldbus

Gateway DTM
DTM representing a device thatconnects different fieldbus segments
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Protocol Annex
Written by technical experts for the protocol
Maps protocol specific requirements and features into the FDT standard
o No changes to the FDT standard or the Frame applications

Provides derived classes and extended base arguments for methods tosupport the protocol specific requirements
Defines required device DTM behavior, for example:ooooIO signals provided by the DTM
Mapping protocol specific data types to FDT data types
Support of scanning method
Handling of communication anomalies

Deliverables include test cases for FDT conformance testing
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CIP Annex Status
FDT 1.2.x annex released in 2008
FDT2 annex under developmento David Comeau is the project leader
o First TRB review this weeko Expected release 1st Qtr 2016

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42EtherNet/IP Demo
An off the shelf demo––––

A free, downloaded FDT Frame
An Ethernet/IP communications DTM
An ATV9xx family device DTM
A Schneider Electric Altivar Process ATV9 Ethernet/IP AC drive

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43Core process industries
What are the characteristics of a chemical plant?
•
•
•
•
•

Marketing Track© 2015 ODVA, Inc.

Big foot printLong term running (~20-30 years)
No plant shut down “button”
Continuous processes without downtime
Hazardous areas

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EtherNet/IP in the field of core process industries“Clear requirements foruse of EtherNet/IP in thefield have to be fulfilled incore process industries”
Chemicals

Oil & Gas

Power & Energy

Primaries &MetalsCore requirements to be fulfilled
•
•
•
•
•

EtherNet/IP in the field ofcore process industries

Information and energy on a single cable
Employable in hazardous areas
Long distances communication between assets
Easy handlingHigh availability

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Physical Layer – Overview and
Demonstration of New Physical Layer
Concepts for Industrial Ethernet andEtherNet/IP in Process Field Devices
Jens Schmidt, Pepperl+Fuchs

Agenda Application area

 Requirements Technical concept
 Live demonstration
 Outlook26.10.2015
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Application area
Standard Ethernet
Engineering Station
Industrial Ethernet (e.g. EtherNet/IP)
Fieldbus (e.g. PROFIBUS, FOUNDATION Fieldbus)
4-20mA (and HART)
Wireless (e.g. WirelessHART, ISA100)

Operator
StationAsset Management Station,
Historian, etc.

Control Domain

L3

L2½

Historian
Network services

Industrial
SwitchControl Network

L2

Wireless
enableddevices
L1

Safety Zone

26.10.2015
EtherNet/IP enabled
devicesMarketing Track© 2015 ODVA, Inc.

www.pepperl-fuchs.com L0

Fieldbus enabled devices

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Requirements 1
Cable length Control Room - Field Junction Box(Trunk)1000 m / 3280 feet

Cable length Field Junction box - Field Device(Spur)

200 m / 565 feet

Connection method (Trunk and spur)

Copper, 2-wire for power + data

Increased EMC immunity

NA 21

Intrinsically safe option

Required

Cable

Today used cable

Connectors

Robust industrial-grade connectors
26.10.2015

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Requirements 2
Number of Field Devices per
Trunkmore than 40

IO data update time

100ms (50 Byte IO) for 32 field devices

Communication performancefor webserver, DTMs etc.

Fluent / adequate

Implementation

Open solution with long time support

Cost aspect

Same order of magnitude than today

Power requirements

Low power to simplify implementation andallow higher number of devices

26.10.2015
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Result of Evaluation

After evaluation of the technologies available today
Pepperl+Fuchs realized that they don’t fulfill the requirements forprocess automation field installations
As an outcome of the evaluation Pepperl+Fuchs decided to design
a new physical layer for Ethernet communication fulfilling therequirements of Process Automation field installations.

26.10.2015
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Concept structure

Controller

PactWare
FDI-i-DTM, Plant PAx
SwitchWLAN
RouterUp to 1000 m

26.10.2015
Marketing Track© 2015 ODVA, Inc.

iPad
Web-Browser

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Control room switch Separate powered Switched technology
 Converts Ethernet (e.g. 4-wire, 100

Ethernet

Mbit/s) to two wire powered Ethernet

Powered, 2-wire,
Ethernet
communication
26.10.2015
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Concept structure

Controller

PactWare
FDI-i-DTM, Plant PAx
SwitchWLAN
RouterUp to 1000 m

Field-Switch
Zone 126.10.2015
Marketing Track© 2015 ODVA, Inc.

iPad
Web-Browser

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Field-Switch
Control room

 Switched connections for instruments
 Switch and instrument powered overdata line
 Intrinsically safe instrument
connection

 Robust industrial-grade connectors

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26.10.2015

Instrumentation www.pepperl-fuchs.com

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Concept structure

Controller

PactWare
FDI-i-DTM, Plant PAx
SwitchWLAN
RouteriPad
Web-Browser

Up to 1000 m

Up to 200 m

Zone 0Field-Switch
Zone 126.10.2015
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Zonewww.pepperl-fuchs.com
2
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Key figures 12-wire system for power and data

Number of devices per trunk: > 60

Usage of IEC-61158 Type A fieldbus cable

Provides all benefits of switch network according to IEEE 802.1

Intrinsically safe option for use in hazardous area Zone 2/Div 2, Zone 1/Div 1 and Zone 0

Low power consumption supports cost efficient Field Device implementation (below 100mW)

More power for advanced device functions

Open implementation based on mass market components (No ASICs)



Redundancy for cable and infrastructure components supported
26.10.2015

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Key figures 2
Communication speed

10 MBit/s up to 500m / 1640 feet

2 MBit/s up to 1000 m / 3280 feet

Auto negotiation and dynamic baud rate switching supported
Requirement: 100ms (50 Byte IO) for 32 field devices
Trunk bandwidth usage of this IO data:

2 MBit/s: 28%



10 MBit/s: 5%
26.10.2015

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Controller

Live Demo
PactWare
FDI-i-DTM, Plant PAx

Pressure transmitter

PROFIBUS PA
SwitchTemperature
Input

Remote I/O

WLAN
RouteriPad
Web-Browser

Up to 1000 m

Control room switch

Up to 200 m

Field switch

Zone 0Field-Switch
Zone 126.10.2015
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Live demo - highlights
 Ethernet network fulfilling field installation requirements for process
automation

 Multi vendor demo proves feasibility of concept
 Integration of complex and simple devices into one homogeneous network
 Major step in communication speed enables upcoming IIoT use cases Compatibility to existing technologies FF, PA and HART offers migration path
 First presentation of field device prototypes utilizing the new physical layer toprovide EtherNet/IP communication
26.10.2015
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60

Outlook The concept shows what is possible today using available technology
 Switched technology and build in auto negotiation support future speed

upgrades when technology evolves
 Basically it‘s only a physical layer. The concept shows a reasonable utilization forprocess automation installations but other usage is also possible.
 Pepperl+Fuchs works with many process automation suppliers to create aninternational and open standard
26.10.2015
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61Demo availability

The demo will be available for more detailed questions andpresentation at the Magnolia room tomorrow and on request

26.10.2015
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62Industry Perspectives on
EtherNet/IP for the Process Industries• Mirko Brcic, ODVA Chairperson for Process SIG• Shannon Foos, Rockwell Automation• Terry Minns, Schneider Electric• Rene Pluis, Cisco Systems• Jens Schmidt, Pepperl+Fuchs• Glenn Schulz, FDT Group• Olivier Wolff, Endress+Hauser

Marketing Track© 2015 ODVA, Inc.

2015 Industry Conference & 17th Annual Meeting
All rights reserved.

www.odva.org

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THANK YOU

Links To Referenced Documents

White Paper Press Release

White Paper

Marketing Track© 2015 ODVA, Inc. All rights reserved.

SIG Formation
Press Release

Work Plan(Accessible by ODVAMembers)2015 Industry Conference & 17th Annual Meetingwww.odva.org

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