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Ethernet I/O

Brad S. Carlberg Jim McConahay


Standards Certification Education & Training Publishing Conferences & Exhibits

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 twentyfive 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
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OSI Model

OSI (Open Systems Interconnect) Model 7 6 5 4 3 2 1

Application Presentation Session Transport Network Data Link Physical


UTP, STP, Fiber, Coax, etc. 10/100/1000/10G speeds
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Ethernet IEEE 802.3x only applies here

OSI Model
Protocols run on top of Ethernet

7 6 5 4 3 2 1

MODBUS, OPC, HTTP, Etc. Presentation Session TCP IP Ethernet Ethernet

What language are you talking?? Protocol

Addressing and Handshaking Protocols

UTP, STP, Fiber, Coax, etc.

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


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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


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Protocol Gateway

What if the protocols dont match? Is there a solution?

Gateway (Protocol Converter) Ethernet to Ethernet Ethernet to Serial Wireless to Serial/Ethernet

HMI, PC, DCS,PLC

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.

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Simplified Gateway Example


Gateway HART Data Map MODBUS Data Map Gateway Internal Mem. MODBUS Slave
68.6

HART Master
68.6

mapping

MODBUS Master gets new data

HART Device is polled

MODBUS Data Map

Internal Mapping Takes Place


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Moving from the Cabinet to the Field


Temperature Considerations 55C vs. 85C operating Temps.

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

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Isolated Channels
Signal Inputs/Outputs

A/D Converter
Common I/O Multiplexer

mP

Typical I/O Card Design -single point of failure -isolation

Signal Input

Signal Input

Signal Input

Signal Input

A/D

A/D

A/D

A/D

mP

mP

mP

mP

Transmitter Like Design -isolation -flexibility of input type

Enhanced I/O Design

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Isolated Channels

Power and Flexibility of PLCs (Cabinet Mounted)

Resolution, Accuracy, and Specs of Field Transmitters (Field Mounted)

Plant Floor Industrialized Ethernet I/O


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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

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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

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

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More Do you need more than I/O gathering?


Ethernet I/O systems are smarter and more powerful than ever. Many times PLCs are used to perform simple control, math and logic functions. Questions to ask your Ethernet I/O vendor 1. 2. 3. Does your Ethernet I/O have the ability to perform control and math? Is the control programming language proprietary?

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Compliant Language Is the programming language 61131-3 compliant?

Function Block Diagram (FBD) Example


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Topology Know your design needs before choosing your Ethernet I/O system
1. Peer-to-HostStar Topology; Bus Topology 2. Peer-to-Peer 3. HybridPeer-to-peer and Peer-to-Host 4. Wireless/Fiber/Copper

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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 Transmitter
Temperature Pressure Level

Direct Temperature Sensors


RTD Thermocouple

Valve Positioners
On/Off Proportional

On/Off Devices
Contact Closure Relay

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

PAIR 1

Ethernet I/O System

Ethernet I/O System

PAIR 2

Ethernet I/O System

Ethernet I/O System

PAIR 3

Ethernet I/O System

Ethernet I/O System

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Add Wireless
Wireless Peer-to-Peer/Host Systems 900Mhz or 2.4Ghz License Free or Licensed

PAIR 1

Ethernet I/O System

Ethernet I/O System

PAIR 2

Ethernet I/O System

Ethernet I/O System

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Security Concerns

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

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Networking
Network Architecture Considerations- Connected
VPN Outside Internet Connections Typical

Front Office Network

Most Convenient but Potentially Vulnerable

Router/Firewall

Process Control Network

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Networking
Network Architecture Considerations- Disconnected
VPN

Front Office Network

Outside Internet Connections Typical

Safer but Inconvenient

No Physical Connection

Process Control Network

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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

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Case Study #1 One communication loop, two bus


Solution: Add MODBUS TCP to Ethernet IP Protocol Converter
Two way FF protocol conversion with PAC
Protocol Converter Converts Modbus TCP to Ethernet IP Foundation Fieldbus Interface Module Modbus TCP FOUNDATION Fieldbus H1 Managed Ethernet Switch Ethernet IP FOUNDATION Fieldbus Transmitters Ethernet IP

FT PT LT FT PT LT

FIM

Local HMI Display

Programmable Automation Controller (PAC)

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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

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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

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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

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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


Ethernet Communications module Discrete input/output module Packaging with switch, klaxon, plus display lamp tree Connection to control panel

Expansion
Add SCADA to ESD at negligible cost
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Case Study #2 Remote ESD for Oil Platform in Gulf


Things at the surface can drop onto sea floor pipelines

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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.

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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

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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

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Case Study #3 Expansion of 4-20mA loops


Data Concentrator on a Peer-to-Peer network
Originally MODBUS Communications Link Currently Ethernet Communications Link

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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

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

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Summary
Our View - Market Trend with Ethernet
1. 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 Microsofts 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.
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2.

3.

Summary
Market Trend with Ethernet Contd
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 Organizations 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, WANs, VPNs, 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.

5.

6.

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Questions?
BSC
Engineering

Thank You!
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