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Executive Summary
In the industrial and manufacturing sector, it’s important to
make the most of the information provided by intelligent
measurement devices. The usefulness of this information
depends on access to and use of real-time, reliable data,
allowing smart choices to be made. Integrating the data so
that effective action gets taken depends on a network
infrastructure that breaks down traditional “silos of
information.”
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Digital Transformation in the Age of IIoT
Table of Contents
Executive Summary...............................................................................................2
Changing User Requirements...............................................................................4
Growth of Automation............................................................................................5
Understanding the IIoT…………………………………………………………………5
A Revolution or Evolution?....................................................................................6
Value of Digital Transformation………………………………………………………..7
Role of Communication Protocols……………………………………………...….….8
Overcoming Implementation Challenges……………………………………………10
Solution for System Integration………………………………………………………11
New Architectural Model………………………………………………………………12
Value to Industrial Organizations…………………………………………………….14
Conclusion……………………………………………………………………………...14
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Digital
Transformation in the Age of IIoT
In a highly competitive global marketplace, industrial organizations are dealing with the evolution of their
businesses and operations, where the virtual world of information systems, the physical world of
machines and the Internet have become one.
The convergence of Operational Technology data into real-time knowledge regarding process
(OT) and Information Technology (IT) is driving performance, equipment health, energy
new methodologies for monitoring production consumption, and emissions monitoring.
processes to improve performance, lower costs
and minimize risk. Mere connectivity of devices Now, more than ever, industrial firms need to
already allows valuable enhancements such as make sense of vast quantities of data having a
remote service and predictive maintenance, but, critical impact on their performance. To support
ultimately, the goal is to analyze data and gain the variety of applications necessary within a
detailed and comprehensive insights from manufacturing facility, information must be
assets, processes and products. delivered with context so it can be understood
and used in various ways by a variety of people.
For modern manufacturers, data needs to
become an integral part of the control and Changing User Requirements
operating system. They require technology
Management of industrial operations has
providing an optimum interface for planning and
become increasingly demanding. It’s a case of
maintenance programs running in the plant.
navigating through the tangle of new data to find
Manufacturers seek “digital intelligence” to
the needle in the haystack. Manufacturers need
manage hundreds or even thousands of assets
to create reliable production plans to meet
from a single site or across an enterprise to
market demands, and synchronize maintenance
address crucial operating demands. This
plans and operations execution – with the
includes effective tools to transform process
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Digital Transformation in the Age of IIoT
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Digital
Transformation in the Age of IIoT
The Internet started in the started with smart connected devices with
unique identifiers communicating using a real-
1960s, but it was not until
time digital network. This led to: having more
the introduction of the
sensors using fewer wires; more measurements
World Wide Web in the in every instrument, with real- time status; the
mid-nineties that most ability to freely add devices to a junction box
without having to run cables all the way to the
businesses could start
Input/Output (I/O) cards or add the I/O cards
realizing the broad themselves; the ability to monitor self-
possibilities of the diagnostics in an instrument from an office on
the other side of the world; and the ability to put
technology. Fig. 2: The IIoT combines the global reach of the Internet with
a new ability to directly control the physical world, an indicator on the network to display values
from transmitters and valves in inconvenient
As the next big step in industrial performance locations, or compute tank inventory or
and operations, the IIoT offers a wide range of compensated flow from multiple sensors.
potential uses and benefits:
Without question, the possibilities of smart
• Enabling businesses to leverage the vast connected devices within an industrial plant are
amounts of data provided by modern endless, and once a connection across the
automation and control systems to make Internet is also provided this value can be
strategic decisions extracted to varying levels within the
organization.
• Providing trained personnel with improved
remote monitoring, diagnostic and asset
A Revolution or Evolution?
management capabilities
The IIoT is often presented as a revolution that
• Enhancing data collection even in the is changing the face of industry in a profound
most dispersed enterprises manner. In reality, it is an evolution that has its
origins in technologies and functionalities
• Improving decisions about the actual
developed decades ago. This technology has
health of assets
been evolving under different names, but there
• Reducing the time and effort for is now a wider acceptance on the market under
configuration and commissioning the common umbrella IIoT.
• Minimizing the need to troubleshoot Many manufacturers that have invested in smart
device issues in the field instrumentation and control systems (i.e., HART
and FOUNDATION Fieldbus) are now looking to
• Bringing production fields online faster leverage existing assets with the IIoT, rather
than abandon or change them. There are also a
Communication protocols and standards form number of organizations that have a long history
the backbone of the IIoT in that they enable the in the advancement of automation products,
secure integration and interoperability of devices driving innovation in open architectures and
and software applications. This results in an digital communication technologies that have
always-connected framework with applications been helping to guide companies through the
such as machine health, predictive analytics, IIoT transformation.
performance monitoring, and asset monitoring
readily layering on top of this infrastructure. Since the introduction of the first smart
transmitter in the 1980s, the market has seen
In the world of process automation, the IIoT continual growth of intelligent field devices that
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Digital Transformation in the Age of IIoT
Fig. 3: Manufacturers that have invested in smart instrumentation are now looking to leverage existing assets
with the IIoT.
are now referred to as “things” with the IIoT. technology and functioning as a gateway to
While the adoption of these “things” has serve data to various enterprise applications via
increased, the approach to developing a more the OPC Unified Architecture (UA).
efficient, profitable and intelligent automation
system is something that many stakeholders Other stakeholders view industrial wireless
have been championing for decades. technology as the answer to retaining large
numbers of 4-20 mA HART-enabled instruments
Field level data can provide huge amounts of and still moving digital information into plant
information, which, if mined, routed to higher networks.
levels and put into perspective is indispensable
for the success of the IIoT. If the data can be Depending upon an organization’s role in the
presented in the proper context to a variety of automation eco-system, its outlook on digital
different users, it can add real value to plant advancement is likely to be very product-
operations. specific, very architectural, or totally aspirational.
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Digital
Transformation in the Age of IIoT
If manufacturers can fully Industrial systems that interface the digital world The IIoT is enabling digital transformation by
to the physical world through sensors and making use of the information contained in
leverage the benefits of
actuators that solve complex control problems installed smart measurement devices.
digitization, all the way are commonly known as cyber-physical Simultaneously, industrial wireless continues to
from core manufacturing systems. These systems are being combined be a valuable, cost-effective solution for quickly
out to the end-user with “Big Data” solutions to gain deeper insight adding more measurements to systems.
through data and analytics. Contributing to digital transformation of
experience, the
measurement data, wireless is being used for
opportunities are Successful digital transformation comes not from monitoring local and remote assets, safety,
exponential because they implementing new technologies but from environmental and many different mobile and
transforming industrial organizations to take rotating measurements.
can better use all of the
advantage of the possibilities that new
available data in the technologies provide. It also results from With a larger, consolidated data set,
enterprise. reshaping operational strategies to leverage manufacturers can apply higher analytics for
valuable existing assets in new ways. more detailed insight, scale the data as needed
to meet the varied needs of single-site or
To get the most out of IIoT and Industry 4.0 enterprise-wide operations and leverage a wider
technologies, and to get past square one with a pool of data experts for monitoring and analysis.
digital business model, companies will have to Ultimately, digital transformation will help
adopt a new way of thinking. It starts with manufacturers eliminate unplanned shutdowns,
recognition that in-place analog solutions are maximize output, minimize safety risk and
sub-optimal and not provide the information optimize supply chain strategies.
needed to run complex industries facilities,
coupled with the belief that networking and
Role of Communication
software technologies underpinning the Internet
have a place in process automation. Finally, Protocols
there is the act of leveraging global The FieldComm Group, formed in 2015 with the
manufacturing technology initiatives by merger of the Fieldbus Foundation and HART
deploying disruptive new technologies to Communication Foundation, is dedicated to
improve safety and performance. developing, managing and promoting global
standards for integrating digital devices into
automation system architectures while
protecting process automation investments in
the HART and FOUNDATION Fieldbus
communication technologies.
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Digital Transformation in the Age of IIoT
highest of levels.
Fig. 5: FieldComm Group technologies provide the means to connect and integrate digital information via the IIoT.
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Digital
Transformation in the Age of IIoT
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Digital Transformation in the Age of IIoT
diagnostics or audit trails – all essential building by the host, including device configuration,
blocks in a modern field device management replacement, maintenance, and diagnostics.
system. This description must be usable for all They must be standardized, usable across all
systems, independent of suppliers of devices, systems, and independent of device suppliers,
systems or tools. Without it, the true potential of system suppliers, or vendor-specific tools.
decentralization, transparency, integration and a
central view of all data and functions cannot be Leading process industry foundations, including
fully realized. FieldComm Group, PROFIBUS International,
and the OPC Foundation, jointly developed the
Solution for System Integration Field Device Integration (FDI) standard to solve
the problem of integrating field devices with the
Today's field instruments look more and more multitude of networks, operating systems, and
like embedded computers. Intelligent, control systems commonly used in process
microprocessor-based devices deployed across plants. FDI takes account of the various tasks
a wide choice of networks transmit a broad over the entire lifecycle for both simple and
range of data that has never been available complex devices, including configuration,
before. But increased data creates an commissioning, diagnosis and calibration.
information management dilemma. How can
users take the huge volume of data created by The core of FDI technology is the scalable FDI
intelligent devices and turn it into actionable Device Package, which describes a field
information? instrument or automation component in all
aspects. No other files are needed. The FDI
The first step is to simplify the procedures Device Package incorporates a device specific
needed to access field device information by Electronic Device Description (EDD) based on
higher-level control or host systems. These the harmonized Electronic Device Description
procedures, known as integration, must be Language (EDDL) per IEC 61804.
completed to assure proper device management
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Digital
Transformation in the Age of IIoT
The big advantage of FDI FDI Device Packages can be processed in FDI With the emergence of the IIoT, however, and
hosts as well as in an FDT2® Frame Application. rethinking of the traditional process network
is it replaces various
This allows device suppliers to create a single view, two crucial questions for the automation
platform-dependent FDI Device Package for their devices – instead industry are:
integration solutions and of separate Device Type Managers (DTMs) and
Device Descriptions (DDs) – while still providing • Where will digital transformation occur?
makes device packages
users the choice of either an FDI host or an FDT
interoperable with host • Where should the Internet Protocol (IP)
host environment.
network exist?”
systems because their
By including all tools, documents, and interfaces
Device Descriptions (DDs) Some believe digital transformation is most
in a single device package, FDI improves
are harmonized across the appropriate at the field device level of sensors
system integration efficiency and allows easier
and actuators with digital-capable devices, while
communication protocols access by IT organizations to OT information.
others think the IP network should reside all the
and host systems. Moreover, it unifies device drivers, configuration
way down in safety-critical systems. In either
tools, diagnostics and documentation regardless
case, security is an overriding factor.
of operating system with an independent and
downloadable software package compatible with Undoubtedly, the classic automation architecture
any FDI-registered host system. is undergoing profound changes to
accommodate IIoT operational strategies. It
Manufacturers and other industrial firms
starts with the ability to connect data and
deploying IIoT applications can connect to
integrate it across the enterprise – only then can
valuable information in intelligent field devices –
value be captured. FieldComm Group protocols
regardless of protocol – by using FDI to
and technologies play a vital role at different
integrate the information in a process control
layers of the new architectural model, and assist
system, asset management tool or Enterprise
with a well-balanced IIoT approach that can be
Resource Planning (ERP) system; then visualize
deployed today and effectively maintained well
and evaluate the data; and ultimately take action
into the future.
based on the information to prevent shutdowns,
lower operating costs, reduce maintenance At the bottom of the IIoT pyramid are “things”
expenses, and become more predictive in how like transmitters, actuators, valves, controllers,
plants are run. monitoring systems, and other familiar
equipment, as well as more recent
New Architectural Model developments such as video sensors and Global
Positioning System (GPS) systems. Above the
The Purdue Enterprise Reference Architecture
physical layer is a fabric of communication and
has been a defining architecture for
control systems that manage field-level devices.
instrumentation, automation, manufacturing
This includes DCS, PLC and safety systems
operations and business planning and logistics
utilizing wired and wireless networks, Radio-
systems since its introduction in the 1990s. This
Frequency Identification (RFID) networks, fiber
pyramid model describes various “levels” of
optics and copper wiring, and run by local or
applications and controls in a manufacturing
remote operators. The third layer consists of IIoT
enterprise. It describes components from the
platforms and processors that take information
physical levels of the plant (Level 0) through
from a plant or multiple facilities, aggregate the
control equipment and strategies (Level 2).
data, and then support tasks such as predictive
Level 3 describes the manufacturing control
maintenance, asset management, advanced
level, and Level 4 is the domain of Enterprise
control, and Supervisory Control and Data
Business Planning, or Enterprise Resource
Acquisition (SCADA). While all this information
Planning (ERP) systems.
is valuable, it is not really actionable without a
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Digital Transformation in the Age of IIoT
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Digital
Transformation in the Age of IIoT
Experience around the utilization of digital intelligence creates more Fieldbus and industrial wireless technologies are
capital investment. Higher field reliability helps also changing how plants are designed.
world has shown IIoT
ensure increased uptime, safer operations, and
devices can improve Thanks to digital networking, end users can now
greater efficiency. Advanced automation
equipment reliability, technology also raises productivity, manages deploy many more sensors in a plant because
assets over their entire lifecycle and optimizes they pay for control loops, while the monitoring
process availability and
experts' knowledge to drive profitable business points are essentially free. This enables new
integrity, and significantly business models like remote monitoring services
results.
reduce maintenance to improve energy efficiency and reliability.
costs. There is significant value to industry as a result
of a smart connected device ecosystem, which
makes it possible to address performance,
reliability, safety, and environmental problems
that have yet to be solved by traditional
approaches. It is becoming possible to securely
get the right information into the hands of
problem-solvers wherever they are located,
whether in a control room on-site or in a factory
somewhere on the other side of the world.
Fig. 10: One of the biggest opportunities to realize IIoT
One of the biggest opportunities for companies benefits is to take advantage of the capabilities offered by
to realize IIoT benefits is to take advantage of plant floor to enterprise data management solutions.
the capabilities offered by plant floor to
enterprise data management solutions. Although While the IIoT can utilize a vast number of
FOUNDATION Fieldbus, HART and WirelessHART connected industrial systems that communicate
technologies have been around for some time, and coordinate their data analytics and actions
the automation industry is still not utilizing their to improve performance and efficiency, and
full capabilities, with a few notable exceptions. minimize or eliminate downtime, there is no
For instance, a 4-20 mA level transmitter simply substitute for human experience and actions to
evolved to became a fieldbus level transmitter or improve operations and reduce costs.
wireless level transmitter, whereas a digitally
networked level transmitter can also provide Conclusion
multi-variables such as pressure and
The drive for digital transformation and smarter
temperature measurement. Some advanced
plant operations, as enabled by developments
new devices like two-wire tank gauging systems,
like the IIoT and Industry 4.0, can help
4/8-input temperature transmitters, intelligent on-
manufacturing firms and other industrial
off valves, and other smart connected devices
enterprises leverage digital technologies to
are already available, and more will be on the
enable rapid deployment of new products,
market soon.
dynamic response to customer demands and
Process industries and instrument real-time optimization of production and supply
manufacturers continuing to 4-20 mA and on-off chain networks through interconnectivity of
signals should revisit plant automation machinery, sensors and control systems. This
architectures, product designs, and decide upon approach also extends to asset management via
new business models to take advantage of the predictive maintenance, statistical evaluation
IIoT, since modern plants have already deployed and measurements to help increase reliability.
it. Most new plants will be built on FOUNDATION
Fieldbus, and existing plants will be modernized
using WirelessHART.
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Digital Transformation in the Age of IIoT
At the heart of IIoT solutions for the process HART and FOUNDATION
References
industries are FieldComm Group technologies Fieldbus represent an
helping automation suppliers and end users Montague, J. (2016). “Exploring the tools, skills
essential platform for
digitally connect to the data revealed by needed to navigate the Industrial Internet of
Things,” Control Magazine, available at: providing vital data, and
increasingly smart instrumentation, and to
integrate the information with enterprise systems http://bit.ly/2d8VNrP these communication
to advance business performance. protocols are
Boudreaux, M. (2016). “What a smart device
It’s worth noting there is a global installed base ecosystem looks like,” Plant Services, available indispensable for
of millions upon millions of FOUNDATION Fieldbus at: http://bit.ly/2dKMtv6 supporting the Industrial
and HART protocol-enabled instruments. Internet and Industry 4.0.
Karschnia, B (2015). “IIoT Business Drivers and
Information from those devices represents
Investment Priorities,” CIO Review, available at:
robust content for IIoT systems. The FieldComm
http://bit.ly/2dydhOX
Group is committed to enhancing the ease of
use of its technologies to enable people – Gill, S. (2015). “Fieldbus: a vital element of IIoT,”
wherever they are located – to access critical Control Engineering Europe, available at:
data. The good news: there’s no need to http://www.controlengeurope.com/article/106157
reinvent existing data models, since they have /Fieldbus--a-vital-element-in-IIoT.aspx
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