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Industrial Ethernet Network

Waskita Indrasutanta, ir.
Wifgasindo Dinamika Instrument Engineering, PT.
Revised August 4, 2003
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Why Ethernet
for Industrial Automation?
International standard market dominance Low cost Ease
of equipment and accessories availability
High performance on different speeds: 10, 100, 1000 Mbps and
faster with auto adjustable speed and packet buffering
IP is a routable protocol connects to LAN and WAN: Connects to
subsystems for APC (Advanced Process Control), Critical
Control, ease of integration for business functions like Online
PIMS (Plant Information Management System), Remote
Monitoring and Control, ERP (Enterprise Resource Planning).
Continuous development
Multi-protocol carrier
Can use different physical media: Fiber optics, IP Radio, etc.
But needs standard application layer to be interoperable
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Is Industrial Ethernet different than
standard Ethernet?
It is the same Ethernet that works based on CD/CSMA
Ethernet is initially designed for IT network that is not
time critical
Industrial applications are very time critical PCN
(Plant Control Network) must be deterministic
network
Harsh industrial environment (extreme temperatures,
high humidity, high vibrations, dust and corrosive
gases, etc.) requires high ratings of equipments
including network accessories
Extra precautions of disturbance, DOS (Denial-Of-
Service) attacks, hacking of the network, or
unawareness of risk in Industrial applications
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Can we make Ethernet
deterministic / real-time?
Dedicated Control Network
Avoid collisions by Industrial Switches
Industrial Protocol
UDP Real-time Secret
Deterministic Software
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Dedicated Control Network
Utilize Dedicated PCN (Plant Control
Network) LAN that is isolated from IT and
other Network by means of Router and
Firewall
Limit the number of IP Nodes make
multiple LAN segments when there are to
many IP Nodes
Generally, limiting network traffic for
industrial control only. This lightly loaded
PCN will give you real-time performance
because it is free and often unpredictable
traffic on the plant-wide network
PCN shall only carry small I/O packets and is
therefore lightly loaded. By only using
fraction of network bandwidth we are
assured that data will always arrive quickly
Full-Duplex network ports simply doubling
the throughput bandwidth
Control Network
FF-H1
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Avoid collisions by Industrial Switch
Hub:
Simply broadcast each message to all ports. When there is more than one
Node (Device) communicating there will be collision and data have to be re-
transmitted randomly only One transmission at a time. Other Nodes have
to wait until ongoing communication is completed. Though wiring looks to be
in Star topology, but communication still work like in Bus topology
Switch:
Will connect Sender port to Recipient port (can be multiple if Publisher
Subscriber relationship protocol being used).
Ethernet Switch can make multiple connections at a time (depending on the
Switch throughput bandwidth) just like the way DPBX works
Use of Industrial Switch that can do fast switching such as cut-through or
slower store and forward technique with large message buffers will certainly
improve the speed of transmission
Utilizing Industrial Switch avoid collision, because the networks is not shared
and therefore multiple communications are possible, i.e. one communication
does not collide with another; Message queue management and performing
automatic speed changes on the appropriate ports.
Industrial Switch has better rating to be able to work in industrial environment
(extreme temperatures, high humidity, high vibration and shocks, etc.)
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Industrial Protocol
Types of Communication
Client-Server (Master-Slave)
Report Distribution (Source-Sink)
Publisher-Subscriber
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Client-Server (Master-Slave)
Relationship
A Client polls the Server
which responds to the
request
Point-to-Point
communication
Also used by Profibus,
HART and Modbus
Central control on
Master-Slave: only one
Master on a single
network; Multiple
(limited) concurrent
Client on Client-Server
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Report Distribution / Report by Exception
Source-Sink Relationship
Source sends out a message to one or more
Receivers (Sinks) acting as temporary Master
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Publisher-Subscriber Relationship
A Publisher sends a
message to one or more
Receivers (Subscriber).
Highly efficient as one
communication reaches
several destinations.
Data reaches all
subscribers at the same
time, enabling
synchronized action,
eliminating jitter.
Used to link function
blocks over the Fieldbus
(FF-H1 & FF-HSE)
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Industrial Protocol
What is TCP/IP?
TCP/IP
IP = Internet Protocol
TCP = Transmission Control Protocol
Defines how message is sent Guarantees message delivery
It takes large messages that have to be broken up for transmission
and reassembles at the receiving end (even if packets arrive out of
order)
Smart enough to reduce traffic if network is getting busy (delay
transmission)
Handles the entire delivery process in reliable manner
Unfortunately, its priority is simplicity for the user and reliability, but
not timelines of the delivery
TCP/IP is great, but it was not designed for real-time
systems
TCP/IP is still widely used in most Industrial Systems that
do not require milisecond response
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Industrial Protocol
UDP Real-time Secret
UDP = User Datagram Protocol
UDP is the actual data packet of TCP delivery system; TCP manage
the delivery of UDP packets; Each UDP packet have an IP Address
and travel on the same network and have the same inner content as
TCP messages UDP is the heart of TCP messages
When we use UDP messaging directly, we have control when to
send each packet. Since operating variables (PV, SP, MV, Status,
Tag, etc) are basically short messages, TCP capabilities of
reassembling large messages is not required. Even if there is a large
amount of data to move, the OPC Server can break it up to
manageable pieces as it does for every other communication media
UDP packets do not carry the overhead of TCP stack (memory
usage and firmware complexity); UDP do not require explicit
sessions to be established between sending and receiving station
and they do not have long timeouts associated with TCP sessions
and delivery mechanism
Industrial Switch will respond to UDP in a much faster manner
making up a real-time network
FF-HSE uses UDP/IP for time critical operating variables and TCP/IP
for other non-time-critical parameters
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Deterministic Software
Fastest network in the world wont give deterministic performance
unless the application software that is sending messages is
structured for real-time results. Most HMI and similar industrial
application software use deterministic I/O polling and utilize real-
time task scheduling techniques
Basic schemes used by I/O Drivers, DDE Servers, OPC Servers
in industrial software is to poll I/O in a deterministic fixed
sequence to ensure repeatable and deterministic results. This
fixed polling guarantees that collisions will not occur is we use
deterministic control network
Depending on the communication type being used, i.e. Client-
Server (Master-Slave), Report Distribution / Report by Exception /
Source-Sink or Publisher-Subscriber, determinism varies (the
latter the more deterministic / real-time)
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Network Security
In Industrial Ethernet application
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System Administration Authority
It is known that IT Engineers are more
competent about computers and network;
I&C Engineers are not as expert as IT
Engineers about computers and networks
tendency that IT Department will take
over PCS system administration
However, IT Engineers have limited
expertise about PCS mistakes will be
very dangerous for the Plant
Administration Rights have to be divided
into different areas:
IT Department shall administer from Router
WAN leg to the entire IT WAN
I&C Department shall administer from Router
PCN leg to the entire Plant Control System
Administration Rights exchange shall be
coordinated between the administration areas
to make entire system to work as designed
PCN
OWS EWS
Supervisory
Control
OPAM
Server
Industrial
Portal
SIS FGDS Other
Subsystems
PIMS
Server
Enterprise Intranet / WAN
Router/Firewall
PCS
Workstation
Workstation
Workstation
Workstation Workstation
Workstation
LINE OF ADMINISTRATION AUTHORITY
Administered
By IT
Administered
By I&C
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High Availability
Fault Tolerant
In Industrial Ethernet applications
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Dual Network set
Workstations
with Dual NIC
Redundant
dual port
Linking device
Redundant
single port
Linking device
Primary Switch Secondary Switch
Single
dual port
Linking device
Device and
Switch
failures can
also be
tolerated
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Loop / Ring Topology
Hub Hub
Hub
Ring-topology fault-tolerant
Proprietary hubs/switches
Standard wire or fiber
Hirschmann Rail-family
Works with and Ethernet device and
protocol
Hub works as splitter
Much faster than spanning tree
One wire failure can be tolerated
Hub failure cannot be tolerated
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Combo / Redundant-Ring
Primary Secondary
Media duplication and complete redundancy in one.
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Thank You
Industrial Ethernet Network
Waskita Indrasutanta, ir.
Wifgasindo Dinamika Instrument Engineering, PT.
Revised August 4, 2003