Ab Magazine 1

Automation
TODAY
January 2015
ASIA PACIFIC
Australia & New Zealand
Inside
Networks vs. Protocols

Machine Security
Water Plant Improves
Performance Efficiency
Machine Builders Improve
Equipment Performance
The Connected
Industrial Enterprise:
Optimised to Create Value
See page 6
EDITORIAL
CONTENTS
Making the Move to

Smart Connected Enterprises
Features
he Connected Enterprise information-driven business

systems that spark enterprise and value chain collaboration
and decisions has been a Rockwell Automation priority for
decades. As its supporting elements evolve, such as the Internet
of Things technologies, the Connected Enterprises growth and
resulting ROI are accelerating.
Moving from simple linked operations to smart connected
enterprises is a process one that involves the connection of
Tom OReilly
operations technology (OT) to information technology (IT). This
connection enables unprecedented collaboration across the enterprise, linking processes
and facilities to suppliers and customers in new ways. It enables manufacturers,
industrial operators and original equipment manufacturers (OEMs) to take advantage of
real-time decision-making that drives profitability.
In striving to help our customers achieve the value of the Connected Enterprise,
Rockwell Automation has pioneered a five-stage process used within and among its own
global manufacturing sites, supply chains and customers. Called the Connected Enterprise
Maturity Model, it incorporates measures and best practices to ensure effective change in
OT, IT and across the organization. It also ensures our customers are securing their data
and infrastructure from internal and external threats. In the process of developing this
Model, Rockwell Automation has also collaborated with leading IT companies.
Stage 1 Assessment: evaluates all facets of an organizations existing OT/IT
network including the information and physical infrastructure; controls and devices that
feed and receive data; and security policies. Stage 2 Secure and Upgraded Network
and Controls: focuses on building an OT/IT backbone to deliver secure, adaptable
connectivity from plant-floor operations to enterprise business systems. Stage 3
Defined and Organized Working Data Capital (WDC): defines and organizes all of
the companys available data for improving business processes. Stage 4 Analytics:
deploys analytics based on the WDC that will deliver the greatest operational return and
drive continuous improvement. Stage 5 Collaboration: creates an environment that
anticipates activities throughout the enterprise and helps the right people make the right
decision at the right time.
Real-time information brings the ability to sense

and manipulate plant processes on the fly.
Every manufacturer will enter and progress through the stages of the Connected
Enterprise Maturity Model at a pace determined by its own needs, infrastructure,
readiness and resources. Rockwell Automation has worked with organizations at
the beginning of their OT/IT intelligence journeys as well as with companies already
leveraging their WDC and collaborating with suppliers.
In this issue of Automation Today Asia Pacific, Rockwell Automation shares its insights
on the Connected Enterprise. The cover article, The Connected Industrial Enterprise:
Optimized to Create Value, describes the key issues related to the Connected Enterprise.
Networks vs. Protocols: What is the Digital Difference? explores the role of Ethernet/IP
in industry. Protect Machines with a Defense-in-Depth Strategy explains the importance of
developing a security framework based on a multi-layer defense-in-depth strategy.
We encourage you to read this issue with an open mind to learn how your company
can make the move to the Smart Connected Enterprise and discover how Rockwell
Automation can help your company connect people, processes and technologies to
reduce costs and improve capabilities.
3 News & Events

Rockwell Automation developments

from around the world.
4 Country News
News and events from around

Australia & New Zealand.
6 Cover Story The

Connected Industrial
Enterprise: Optimised to
Create Value

Security is a key element in enabling

manufacturers to leverage the Internet
of Things (IoT) to help connect people,
processes and technology and achieve
operational excellence.
10 Networks vs. Protocols:

What Is the Digital
Difference?

EtherNet/IP uses the tools and technologies

of unmodified Ethernet, which has steadily
evolved to provide high performance and
network intelligence.
12 Protect Machines with

a Defence-in-Depth
Strategy

The defence-in-depth concept identifies

and analyses potential internal and external
security threats to production equipment.
14 Application Story

Rockwell Software enables water plant

to improve performance efficiency and
meet regulatory compliance.
16 Application Story

Pohokura production station sets

the standard for remote operation &
sustainability.
18 OEM Innovations

Rockwell Automation helps OEMs

customise their machines.
21 Product Focus

Recent additions to the Rockwell Automation

product portfolio.
Automation Today is published by

ROCKWELL AUTOMATION SOUTHEAST ASIA PTE LTD
2 Corporation Road, #06-01 Corporation Place,
Singapore 618494
Tel: (65) 6622 5141 Fax: (65) 6622 5100
Editor: Victor Lim vlim@ra.rockwell.com
ROCKWELL AUTOMATION AUSTRALIA
Tel: (61) 3 9757 1111 Fax: (61) 3 9729 1418
Contact: award@ra.rockwell.com
Copyright 2014 Rockwell Automation Inc. All rights reserved. The contents of this publication
may not be reproduced in whole or part without the consent of the copyright owner. AllenBradley, CompactLogix, Connected Components Workbench, ControlFLASH, ControlLogix, E300,
Encompass, FactoryTalk, Guardmaster, Integrated Architecture, Kinetix, Micro800, MP-Series,
PanelView, PlantPAx, PowerFlex, Rockwell Automation, Rockwell Software, RSLinx, RSLogic,
RSNetWorx, RSTestStand, RSView, Stratix 2000, Stratix 5100, Stratix 5700, Stratix 5900,
Stratix 8000, Stratix 8300, Studio 5000, Total Cost To Design, Develop and Deliver and Vantage
Point are trademarks or registered trademarks of Rockwell Automation, Inc.
Catalyst and Cisco are trademarks of Cisco Systems, Inc.
Tom OReilly, President | Rockwell Automation, Asia Pacific Region
EtherNet/IP is a trademark of the ODVA.

Ethics Quotient, Ethisphere and Worlds Most Ethical Companies are trademarks of the Ethisphere Institute.
Panduit is a trademark of the Panduit Corporation.
Excel, Microsoft and Windows are trademarks of the Microsoft Corporation.
January 2015 AUTOMATION TODAY ASIA PACIFIC
Trademarks not belonging to Rockwell Automation are property of their respective companies.
NEWS & EVENTS

Dalian Campus
Product Transition
2012
FactoryTalk ViewPoint
2010
Connected Components
Workbench software
2009
RSLogix 5000 Compare Tool
FactoryTalk
FactoryTalk AssetCentre
RSLogix Architect
RSMACC
2008
ControlFLASH software
FactoryTalk Live Data
RSLinx Enterprise
2007
Alarms and Events
FactoryTalk Activation Manager
FactoryTalk Gateway
FactoryTalk Transaction Manager
2006
FactoryTalk Historian SE
RSTestStand Enterprise
2005
FactoryTalk Historian Classic
FactoryTalk Scheduler
FactoryTalk Metrics
RSLogix 5000
2004
FactoryTalk View
RSNetWorx
2003
RSLinx Classic
RSLogix 500
2002
RSView32
1999
Entrx
1994
EMONITOR
Dalian Software R&D

Campus Celebrates
20th Anniversary
ockwell Automation recently celebrated the

20th anniversary of its software research
and development campus in Dalian, China.
Over the past two decades, it has evolved from a
two-engineer operation to the companys largest
software R&D center outside the United States.
The campus focuses on new product development
and innovation. It supports the companys strategy
around The Connected Enterprise, bringing smart,
safe and sustainable manufacturing to life by
prioritising research on enhancing the integration
of control and information systems.
Rockwell Automation Chairman and CEO Keith
Nosbusch says, I continue to be impressed by how
our Dalian campus has evolved into a truly great
asset for our global R&D capabilities, providing
support not only for our global customers but
also serving local customers in China. China is a
strategic and important market for our continued
global success, and it is our long-term strategy to
strengthen our innovation capabilities in China and
cultivate more local talent to better serve the China
market.
The convergence of control and information
technologies coupled with new technologies
such as mobility, cloud and big data analytics is
reshaping the manufacturing landscape. The Dalian
campus will play a significant role in supporting the
Rockwell Automation vision for The Connected
Enterprise.
BRIEFS
Cybersecurity Framework
Reduces Risks to Critical
Infrastructure and
Manufacturing
Rockwell Automation has endorsed
the Cybersecurity Framework of the
National Institute of Standards and
Technology. The voluntary framework
reflects
input
from
Rockwell
Automation and a diverse group of
industry stakeholders who share a
common objective to increase the
resiliency of and reduce cybersecurity
risks to critical infrastructure and
manufacturing.
Cisco Internet of
Everything Partner
Rockwell Automation recently
announced that it has been awarded
the Cisco Internet of Everything
Partner of the Year at the Cisco
Australia and New Zealand Partner
Insight Awards in Melbourne.
The award celebrates innovation,
leadership and excellence within the
business community. Award criteria
include innovative and architectureled approach to success, business
differentiation and strategic outcomes,
and deep customer understanding.
Ethisphere Institute Honors Rockwell

Automation
or the sixth time, the Ethisphere Institute has named Rockwell Automation as one of
the Worlds Most Ethical Companies, a recognition that honors organisations that
continue to raise the bar on ethical leadership and corporate behavior.
The Ethisphere Institute is an independent centre of research promoting best
practices in corporate ethics and governance. Worlds Most Ethical Companies honorees
understand the correlation between ethics, reputation and business success.
The Worlds Most Ethical Companies assessment is based upon the Ethisphere Institute
Ethics Quotient framework. Scores are generated in five key categories: ethics and
compliance program (25%); reputation, leadership and innovation (20%); governance (10%);
corporate citizenship and responsibility (25%); and culture of ethics (20%).
Rockwell Automation also announced that its latest Corporate Responsibility Report
is now available online and in print. The report highlights updates on the companys
environmental performance, employee safety and culture, and community relations efforts.
To learn more, visit:
http://www.rockwellautomation.com/
rockwellautomation/about-us/sustainability-ethics/integrity-complianceoverview.page?
AUTOMATION TODAY ASIA PACIFIC January 2015
COUNTRY NEWS
FIRST Robotics brings Regional event down under in 2015
Robot mania is set to hit Sydney as

robots race to compete in the FIRST
(For Inspiration and Recognition of
Science and Technology) Robotics
Competition (FRC). FIRST, worlds
leading robotics program will host the
first Australias regional competition
at the Sydney Olympic Park Sports
Centre on March 11-14, 2015. Teams
from Australia and around the world
will take part in the FIRST Robotic
Challenge (FRC) Regional event.
This will be the first time that
were holding a regional competition
in Australia so its great to see that we
already have teams registering from
not only around Australia but also
other countries including, Hawaii,
Brazil, Taiwan, China and Singapore,
said Luan Heimlich, Regional Director
for FIRST Australia.
In this event, teams will have about

six weeks to brainstorm, design,
prototype, build, program and learn
to drive a robot before putting them
to the ultimate test in this large scale
robotics competition. The robots
themselves are up to two metres tall
and weigh as much as 50 kilograms.
In addition to competing in the
robotics game, participants are also
in the running for three prestigious
awards; the Chairmans Award,
Engineering Inspiration Award and the
Rookie All-star Award. The winning
alliance and these award winners will
be invited to compete in the FIRST
World Championship event, to be held
in St. Louis, Missouri, USA.
FIRSTs mission is to inspire young
people to be science and technology
leaders, by engaging them in exciting
mentor-based programs that build

science, engineering and technology
skills, that inspire innovation,
and that foster well-rounded life
capabilities including self-confidence,
communication, and leadership.
As one of the key global sponsors
for FIRST, Rockwell Automation is
committed to encouraging students
to study a science, technology,
engineering or maths (STEM) field
at university. The company was the
recipient of the Founders Award at
the 2013 World Championships for
their continued sponsorship of FIRST.
Rockwell Automation is a great
supporter of FIRST. The program
has really taken off in Australia, we
started small but we now have 30
teams. I think that once people talk
to participants in the program, they
really see and understand the power
of the program and then look to
becoming involved, said Heimlich.
The theme for next years Regional
event will be announced closer to the
date but will no doubt combine the
excitement of sport with science and
technology to create a unique varsity
Sport for the Mind. FRC helps
young people, aged 14-18, discover
the rewarding and engaging world of
innovation and engineering.
To see FIRST in action visit
Australias first Regional Event at the
Sydney Olympic Park Sports Centre
from 11-14 March, 2015.
Automation University is coming to a town near you

Rockwell Automation is pleased to
announce that Automation University
will be touring regional centres around
Australia and New Zealand throughout
2015. Following the success of
previous years, this one-day event will
highlight leading-edge automation
solutions.
According to Matthew Treeby,
commercial marketing manager at
Rockwell Automation, Automation
University will provide a unique, in
depth experience with technology. We
have designed a program that is full
of insight, vision, ideas and practical

solutions to help participants stay
ahead of their competition.
Technology is moving at such a fast
pace that organisations cant afford to
be left behind, but may also be short
of time to keep up with the latest
advances. To help organisations meet
their business and plant requirements,
Automation University will provide
the platform to bring together people
and products, as well as technologies
and solutions, he explained.
Attendees will have the valuable
opportunity to learn by experience

through interactive demonstrations,
hands on labs and presentations that
show real-life industry environments
and scenarios. Rockwell Automation
specialists and industry leaders from
our PartnerNetwork will lead each
session. Each location will offer two
or more streams, focussed on topical
themes to ensure attendees can design
their personal workshop program and
follow technology sessions of their
choice.
Rockwell Automation is committed
AUSTRALIA & NEW ZEALAND
Rockwell Automation and Cisco deliver networking technologies training

course throughout 2015
The Internet of Things (IoT)
has emerged as one of the most
transformative and growing
technology trends today. As the
industrial plant floor and corporate
enterprise become more connected,
the demand for skilled professionals
who understand the exchange
between information technology (IT)
and operations technology (OT) is
increasing.
Establishing a connected industrial
enterprise may appear to be an
overwhelming challenge but it is one
that manufacturers must address to
remain competitive in the current
marketplace.
In response, Rockwell Automation
together with Strategic Alliance
partner Cisco, has launched a new
training course, Managing Industrial
Networks with Cisco Networking
Technologies (IMINS). This is a

hands-on lab-based course, which
helps students with the foundational
skills needed for the management and
administration of networked industrial
control systems.
According to Cuong Vo, business
manager, Customer Support
& Maintenance at Rockwell
Automation, Automation engineers
are increasingly required to manage
networked industrial products and
solutions so this course is designed
for IT and OT professionals and
control engineers who are involved
with the implementation, operation
and support of networked industrial
products and solutions,
This course aims to enable
participants to achieve competency
and skills to install, maintain and
troubleshoot industrial network
systems while
helping to
ensure network
availability,
reliability and
Internet security
throughout their
companies, he
said.
Industrial
IoT technologies
to helping customers succeed and

gain a competitive advantage through
hosting events such as Automation
University. From stand-alone,
industrial components to enterprisewide integrated systems Rockwell
Automation solutions have proven
themselves across a wide range of
industries and environments.
Whether you are an engineer, end
user, machine builder or consultant,
visit Automation University for up to
date, views, trends and technologies of
integrated information and automation
solutions.
The Automation
University
events are
completely
free of charge
but places are
always in great
demand, so
anyone wishing
to attend is
encouraged to register early. Dont
miss this unique opportunity to see,
touch and experience the complete
can help customers lay a foundation

for a highly secure, connected
enterprise using standard unmodified
Ethernet to connect people, processes,
data and things. This ultimately drives
greater productivity and sustainable
competitive differentiation.
The five-day course focuses on
networking technologies that are
needed in todays connected plants
and enterprises. Participants will
get hands-on experience working
with the Rockwell Automation
suite of products to help converge
technologies and bring the value of
the connected enterprise to life. It
also provides a foundation for the
Cisco Industrial Networking Specialist
Certification exam.
Rockwell Automation and Cisco
have been working together to bridge
the gap between enterprise IT and
plant floor operations technology
professionals through network
and security products, Converged
Plantwide Ethernet (CPwE) reference
architectures, services and solutions.
The IMINS training course will be
conducted as part of the Rockwell
Automation ConnectED 2015 and
Cisco Live 2015 in Melbourne from
16-20 March and subsequently in other
locations around Australia.
offering from Rockwell Automation.

For more information visit:
www.rockwellautomation.com.au
The Connected
Industrial Enterprise:
Optimised to Create Value
Security is a key element in enabling manufacturers to leverage the

Internet of Things (IoT) to help connect people, processes and technology
and achieve operational excellence.
stablishing a Connected Enterprise

is more complex than simply
connecting disparate systems.
It means having access to real-time
and historical data, wherever its being
produced, and all of the business and
transactional data that will affect different
plants and their operations.
It
involves
seamlessly
and
securely connecting all control and
information levels of an organisation.
As the historic disconnect between
enterprise and plant-floor networks is
bridged, industrial firms need to better
understand potential security risks.
Whether its your network, assets
or intellectual property, operations
need to be secure from potential
threats whether theyre accidental or
intentional, internal or external.
When we speak to our customers

about moving a Connected Enterprise
forward, its not unusual for them
to raise two concerns: cost and
security, says John Nesi, Rockwell
Automation vice president of global
market development. As we discuss
this, we have to realise that the vision
of the Connected Enterprise includes
value creation.
By letting people know whats
really happening in the enterprise,
the Connected Enterprise creates
real customer value by turning data
into information into knowledge and,
ultimately, into wisdom, says Keith
Nosbusch, chairman and CEO, Rockwell
Automation. This requires a common,
secure Ethernet infrastructure to
integrate control and information.
LEARN MORE ABOUT

THE CONNECTED ENTERPRISE
isit these resources to learn

more about the Connected
Enterprise and how it can make
a real difference in your operations.
Video: Rockwell Automation

President and CEO Keith
Nosbuschs Keynote
Presentation The Connected
Industrial Enterprise from
the 2014 Internet of Things
World Forum
Video: RSTechED 2014
Presentation about the
Connected Enterprise and
Industrial Security
Free White Paper:

The Connected Industrial
Enterprise [PDF]: Why
Unlocking Data to Enable a
Connected Enterprise is Vital
to the Future of Manufacturing
Websites: Learn more about
the Connected Enterprise at
www.rockwellautomation.com/
rockwellautomation/
innovation/connectedenterprise/overview.page?.
Also visit www.industrial-ip.
org/community/blog.
That value opportunity comes

directly
from
the
technology
opportunity. Having the technology
and the knowledge to distill all of
the business and transactional data
into information that provides true
innovative value is the next frontier,
Nesi says.
Technology Transformation
Were in the middle of a technology
transition that has a big impact on
business, explains Rob Soderbery,
senior vice president and general
manager of the Enterprise Networking
Group at Cisco, a Rockwell Automation
Strategic Alliance Partner. According
to Soderbery, three macro trends are
influencing that transition:
1. The economics of the growth of
emerging vs. developed countries.
2. Energy consumption and what
the demands and sources will be
in the future.
3. Social demographics of hyper
growth in emerging markets, and
declining workforce and aging
population in developed countries.
Productivity, he adds, will be at the
heart of solutions dealing with these
issues. The next wave of productivity
will come out of the Internet of
Things, or IoT. The IoT includes
the seemingly infinite number of
devices and their interconnectedness
via Internet Protocol (IP). By 2020,
it is estimated that there will be
50 billion connected things connected
to the Internet.
In fact, Cisco says theres
$14.4 trillion in increased value to be
realized in the private sector over the
next 10 years in the IoT. That value,

notes Soderbery, will come from
benefits in innovation expansion,
enhanced customer experiences,
asset
utilisation,
employee
productivity, and supply chain and
logistics improvements.
He adds that about $3.7 trillion
of that $14.4 trillion will come in the
manufacturing sector.
But the big impact, the stunning
opportunity here, is in industry, he
says. When you can connect things,
processes and data in the cloud, you
can create new real-world applications
in logistics, in segments that are
upstream in the supply chain. The
cloud offers remote access to devices
and information, massive storage
and the computing power needed for
complex analytics.
In addition to remote access, people
want the ability to access information on
the go, making security a high priority.
Big data and analytics empower
collaboration, and manufacturing
generates more big data than any other
sector, says Nosbusch.
Security at the Forefront

Clearly, many challenges exist, from
converging and merging disparate
networks, to harvesting distributed
intelligence by pushing analytics out
to the data sources, to ease of use.
However, the one that trumps them all,
Soderbery says, is security.
So why is IoT security different? One
of the reasons is the attack surface.
Soderbery explains, The attack
surface of a factory is large and
complex. Remediation also is different.
What do you do if youre under attack
in the process industry? Shutting down
is not a practical or easy response.
He presents a few ideas for IoT
security. Access control is more than
a firewall. You have to be aware of the

content on the network through tools
like deep-packet-inspection engines.
A second thing is the context. Whats
the device, what data does it produce,
is it where it says it is? You can
draw some conclusions through the
combination of content and context.
This contributes to improved threat
awareness and an understanding of
the threat landscape.
Mike Assante is advisor and director
for the National Board of Information
Security Examiners. He is the SANS
Institute project lead for industrial
control system (ICS) and supervisory
control and data acquisition (SCADA)
security. He says that the desire for
analytics isnt just restricted to the
manufacturer and its supply chain.
Companies such as the equipment
and machine builders themselves want
access to the equipment they sold you,
and want to better understand the
operating envelopes of those machines
to help optimise those machines and
enable them to perform more safely,
he explains.
Assante notes that threats to
industry are becoming more targeted
and structured. He reports that up to
94% of those targeted attacks arent
discovered by the victim until they
learn about it through a third party, or
learn that some of their information
was found on someone elses server.
In all these reported cases,
says Assante, the companies were
up-to-date with their antivirus solutions
and used industry security practices,
but still were compromised. It tells us
that our conventional security approach
isnt working for that type of threat.
Its time to adapt, he proposes.
Assante explains that we have to secure
our people first and recommends
that automation engineers work with
cyber-security personnel and viceversa to cross-educate their strengths

and needs. This can lead to new
approaches to better security.
Bringing the Cloud

Down to Earth
Some wonder how the cloud and the
IoT will affect their daily work lives in
the industrial plant.
To us, big data means all the
information running on plant floors, so
our mission is to help our customers
find the best ways to make sense of
THE POWER IN
STRATEGIC
ALLIANCES
ockwell Automation and its

Alliance Partners are committed
to
helping
manufacturers
improve business performance by
bridging the technical and cultural gaps
between plant-floor and higher-level
information systems. For example,
Rockwell Automation works with
Cisco, a worldwide leader in Internet
networking, on various initiatives,
including joint products and solutions.
Cisco and Rockwell Automation

developed the Stratix 5700,
Stratix 8000 Layer 2 and the
Stratix 8300 Layer 3 managed
industrial switch lines, creating a
networking environment for both
IT and controls professionals.
Using the current Cisco Catalyst
switch architecture and feature
set, along with configuration
tools, the product line helps to
provide secure integration with
the enterprise network. Visit www.
rockwellautomation.com/partners/
cisco.html for more information.
FEATURE STORY
OEMS IN THE
IoT PLANT
s organisations seek greater

visibility into their operations,
OEMs must help establish
a smooth flow of information from
the machine level to the enterprise.
Below are the steps OEMs can take
to securely integrate machines and
equipment into a plant network,
protect intellectual property at the
machine level and provide secure
remote access for end customers.
1. Control who has network

access using tools, such as
access control lists and portblocking features/devices.
2. Employ firewalls and intrusion
detection/prevention.
3. Use anti-virus protection
and whitelisting.
4. Establish a system-patching
policy to keep software
up to date.
5. Develop procedures for
employee-security practices,
such as managing and
protecting passwords, managing
removable media and use of
personal devices.
6. Physically block changes to
your controller by putting it
in Run Mode.
7. Control who is allowed to
do what from where in the
application with FactoryTalk
Security architecture.
8. Monitor what is going on in your
system with Controller Change
Detection and FactoryTalk
AssetCentre system.
9. Protect your intellectual
property with Logix Source
Protection.
10. Ensure all Ethernet devices
are connected using standard
Internet Protocol.
it all, says Keith McPherson, market

development
director,
Rockwell
Software. We help users connect to
their information, organise it, put it into
the right context, set up dashboards
and distribute it to the right individuals
who can make better and more
profitable decisions.
He continues, Over a decade ago, we
made a decision to base the Integrated
Architecture system on standard,
unmodified Ethernet. Thats whats making
it easier for us to implement the virtual
computing and cloud-based services so
many users are asking for now.
Rockwell Software now offers its
FactoryTalk VantagePoint Mobile
App in the Windows Store, which is
based on the FactoryTalk VantagePoint
enterprise manufacturing intelligence
(EMI) software, Version 5.0. Featuring
Windows 8-style on-screen tiles,
this new app can provide any key
performance
indicators
(KPIs)
users need right at their fingertips,
McPherson says.
To help support these apps, big
data and cloud-based projects with
some
heavy-duty
virtualisation
hardware, Rockwell Automation
offers its Industrial Data Center, a
pre-engineered, scalable infrastructure
that lets users run multiple operating
systems
and
applications
on
virtualised servers. It includes an
enclosure and temperature controls
by Strategic Alliance Partner Panduit,
and Unified Computing System
(UCS Servers and Catalyst switches)

from Strategic Alliance Partner Cisco.
It has the ability to run a virtualised
PlantPAx system and a variety of
FactoryTalk and other third-party
software packages on a users private
cloud.
More Demand,
More Attention Needed
As the global population accelerates
toward 8 billion, millions of people
are exiting poverty, and an expanding
middle class will demand more food,
housing and transportation goods
that will have to be manufactured
and distributed. This will increase
demands on manufacturers and on
infrastructure, water supply and raw
materials. Increasing demand for scarce
resources will drive inefficiencies out
of manufacturing, leading to a need
to spend an estimated $1 trillion on
resource productivity, Nosbusch says.
We believe that we are at an inflection
point drawn by the integration of the
Internet of Things and the Connected
Enterprise, he says.
That makes attention to security
even more vital as the Connected
Enterprise and technology that
supports it enables the collaboration
among people, plant-floor systems and
the enterprise for seamless, secure,
productive operations. (See the article
in this issue entitled Protect Machines
with a Defence-in-Depth Strategy.) AT
Scalable
Modbus Solutions
L3x
Our Enhanced Modules support

big data initiatives (up to 10,000
words) from many devices (20
clients and 20 servers).
L2x
Our Lite Modules support

up to 240 I/O words for
smaller applications.
L1x
Integrated Modbus Serial

communications in
1734 Point/IO
applications.
Whether your CompactLogix Modbus application is large or small,

we have your connectivity solution.
For more information, visit:
http://psft.com/ATAP
+60-3-7724-2080
asiapc@prosoft-technology.com
Where Automation Connects
www.prosoft-technology.com
ASIA PACIFIC | AFRICA | EUROPE | MIDDLE E AST | L ATIN AMERICA | NORTH AMERICA
TECHNOLOGY WATCH
Networks vs. Protocols:

What Is the Digital Difference?
EtherNet/IP uses the tools and technologies of unmodified Ethernet, which has steadily
evolved to provide high performance and network intelligence.
ike many words in the English

language, network and protocol
have different meanings, depending
on the context. For example, your
interpersonal network is far different
from a railway network. In the context
of digital communications, the MerriamWebster dictionary defines network as
a system of computers, peripherals,
terminals, and databases connected by
communications lines.
The worlds most common

computing network is Ethernet,
uniformly defined under IEEE 802.3.
More than 85 percent of the worlds
LAN-connected PCs and workstations
Internet Protocol (IP), explains

Paul Brooks, business development
manager, Rockwell Automation. The
vast majority of digital developers
worldwide use IP to continuously
advance information handling and
task management.
IP is the primary protocol
that
supports
todays
global,
multimedia
information
and
communications system. Relying
on an open-architecture networking
environment primarily standard
Ethernet IP has enabled the invention
and interoperability of a vast array of
electronic communication devices.
IP is the primary protocol that supports

todays global, multimedia information and
communications system.
rely on standard Ethernet, which
allows seamless networking of
electronic devices, regardless of their
operating system.
Protocols, in the context of
digital
communications,
require
a slightly longer description in
Merriam-Webster: For computers to
exchange information, there must be
a preexisting agreement as to how the
information will be structured and
how each side will send and receive
it. Without a protocol, a transmitting
computer, for example, could be
sending its data in 8-bit packets while
the receiving computer might expect
the data in 16-bit packets. Protocols
are defined by international or
industry organisations, such as the
IEEE and the Internet Engineering
Task Force (IETF).
Critically, the definition points out
that the most essential and powerful
of these technical standards is
10
IP: The Powerhouse Protocol

IP provides the common electronic
language that allows different devices
not only to coexist on a network but
also to interoperate. IP organises
data into a common digital structure,
enabling everything from computer
hardware and software to cell phones
and smartphones to interact and
connect to the Internet.
While IP is commonly referenced as
part of the TCP/IP protocol suite (TCP
standing for Transmission Control
Protocol), IP is the powerhouse of
the pair. It implements key network
functions, including addressing,
packet handling and routing. IP also
is the foundation on which other TCP/
IP protocols, as well as numerous
applications, are built.
IP functions at the Network Layer
(layer three) in the Open Systems
Interconnection (OSI) reference
model. That means it runs on top
of the physical and data-link layers

defined by IEEE 802.3 otherwise
known as Ethernet.
These two standards are not only
formally recognised, their combined
use is nearly ubiquitous except in
a portion of industrial automation.
Traditionally, many manufacturers
have relied on dedicated, purposebuilt proprietary networks for the
plant floor automation, with the rest
of the enterprise communicating via
standard, unmodified Ethernet.
This has contributed to a digital
divide between plant- and sitewide operations and the overall IT
infrastructure, often creating islands
of automation in the manufacturing
realm, says Brooks. Without standard,
unmodified Ethernet on the plant
floor, many industrial automation
companies cant easily take advantage
of higher-level protocols and the
immense functionality they support
including FTP, to send files; SMTP,
to send emails; HTTP, to browse the
web; and VoIP, to transmit calls.
Equally important, the majority
of network security innovations are
designed to work in conjunction
with IP. Cisco estimates that global
cybersecurity
investment
will
exceed $86 billion in 2016, and the
UKs National Audit Office believes
that 80 percent of enterprise-level
attacks could have been prevented
through deployment of commercially
available technology.
Some protocols have been built
specifically for industrial applications,
such as the Common Industrial
Protocol (CIP). It encompasses a
comprehensive suite of messages
and services for the collection of
industrial automation applications
control,
safety,
synchronisation,
motion,
process,
configuration
and information. It is important to
remember that Ethernet is just a

transport mechanism, and it is the
upper-layer protocols riding on top
of it that enable true interoperable
communication. Thus, CIP provides
a unified communication architecture
throughout the plant- or site-wide
network infrastructure.
Standard Ethernet vs.

Ethernet-Based
Why havent all automation
companies
adopted
standard
Ethernet-enabled IP? The reasons
vary, though most are rooted in the
fact that the plant floor is a much more
rugged and demanding environment
than the average office, and its
networking demands are different.
Instead of accessing files and
printers, Brooks explains that plant
floor controllers must access data
embedded in controllers and drive
systems, operator workstations and
I/O devices. Plus, plant floor data
communications needs are real-time,
or very close to real time.
Also, in the past, standard Ethernet
equipment and cabling lacked the
durable,
ruggedised
industrial
strength necessary to stand up to
tough conditions often found on
plant floors. Those reasons for
resistance have been well overcome
by advances like EtherNet/IP, which
combines unmodified Ethernet, IP
and CIP. Furthermore, hardened
hardware, ruggedised cabling and
other equipment have also helped to
dispel some Ethernet doubts.
Still, some manufacturers have
remained tied to the proprietary
plant networks of the past, or theyve
been convinced by entrenched
vendors
that
Ethernet-based
technology is equal to standard,
unmodified Ethernet.
It is not.
Derivatives of IEEE 802.3 and
more importantly, the TCP/IP
protocol suite often dont come
with the same capabilities. So, for
example, manufacturers that do not
use standard Ethernet and TCP/ IP
technologies often cant seamlessly
connect the plant networks to the rest
of the IT infrastructure without using
special hardware or protocol gateway

devices. Such add-on technology can
add cost and complexity to network
owners. These additional items
also add one more point of system
configuration or failure. Furthermore,
they may be tied to a limited vendor
supplier set or technicians.
What do we mean by seamless?
We mean the ability to do real-time
routing outside of a layer 2 LAN or
layer 3 subnet. Or, said another way,
no data mapping!
EtherNet/IP =
IEEE.802.3 + IP + CIP
Manufacturers
that
rely
on
EtherNet /IP as their industrial
network can seamlessly share plantwide information. Thats because
EtherNet /IP is truly an IEEE 802.3
standard. And, it adheres to the
wireless standard, 802.11.
EtherNet/IP uses the tools
and technologies of unmodified
Ethernet, which has steadily evolved
to provide high performance and
network intelligence. Speeds have
risen from 10 Mbps to 100 Mbps to
one gig and beyond.
Meanwhile, engineering enhancements have made EtherNet/IP a
multi-discipline platform, converging
operations with plant-floor control,
motion, process and safety applications. Thus, EtherNet/IP enables

organisations to save money by
moving away from expensive, closed,
plant floor dedicated networks.
EtherNet/IP
provides
users
with the tools to deploy standard
Ethernet technology for industrial
applications. The result: performance
and data anytime, anywhere.
In addition, EtherNet/IPs familiar
Internet technology means users can
more quickly and easily learn how
to operate systems connected to
the network. Plus, without separate
networks to worry about, engineers
can more easily and quickly integrate
machines into the plant, significantly
lowering start-up costs.
Today, a broad range of
EtherNet/IP product lines are
offered by more than 300 vendors
worldwide. EtherNet/IP also works
transparently with all standard,
off-the-shelf Ethernet devices found
in todays marketplace and can be
easily supported on standard PCs
and their derivatives.
EtherNet/IP allows users to put the
full power of the Internet Protocol to
work for industry, now and far into
the future. AT
This graphic shows adherence to IEEE 802.3 and the IETF TCP/IP protocol suite while also
illustrating that real-time communication is guaranteed.
11
TECHNOLOGY WATCH
Protect Machines with a

Defence-in-Depth Strategy
The defence-in-depth concept employs multiple layers of security controls to protect
the integrity of components or systems.
he
increasing
adoption
of
in
production
is
EtherNet/IP
being accompanied by increasing
convergence between operations and
business systems. This gives operations
professionals broader and deeper access
to production data and the elements that
support them.
Business and production managers

can quickly access the relevant levels
of information, enabling them to make
decisions based on real-time data.
However, the convergence of the
office
and
production
systems
also requires security strategies
particularly for the production network,
as it is no longer an isolated network
within the company.
Rockwell Automation, working
with its collaborators, has adopted a
security framework that is common
between the manufacturing and
enterprise network. The concept,
based on a defence-in-depth
strategy to protect production assets,
warrants a closer look.
Examining the Strategy

The defence-in-depth concept uses
multiple security countermeasures to
protect the integrity of components
or systems. It is based on the idea
that any one point of protection may,
and probably will, be defeated. This
approach requires multiple layers of
defencephysical, network, computer,
application and deviceto help ensure
a weakness or flaw in one layer can
be protected by strength, capabilities
or new variables introduced through
other security layers.
For example, physical security
mechanisms such as guards and
gates limit physical access of areas,
control panels, devices, cabling, the
control rooms and other locations to
authorised personnel. Network security
applies to the network infrastructure,
12
such as firewalls with intrusion

detection and intrusion prevention
systems (IDS/IPS), and integrated
protection of networking equipment,
such as switches and routers.
At the computer layer, patch
management
and
antivirus
software as well as removal of
unused
applications,
protocols
and services help to harden the
hardware from attacks. Application
security relies on authentication,
authorisation and audit (AAA)
software to help prevent unauthorised
access or changes. At the device layer,
change management, communication
encryption and restrictive access help
to harden factory-floor devices.
A
systems-oriented
approach
to industrial security can help
manufacturers proactively assess
and address risks in their control
systems.
Rockwell
Automation
teams with industry leaders to help
manufacturers and machine builders
incorporate these layers of security
into machinery.
Elements of
Automation Security
Control systems, networks and
software, as key elements of an
overall security strategy, can help
defend against security threats and
risks in manufacturing.
For
example,
programmable
automation controllers (PACs), humanmachine interfaces (HMIs), drives, and
other intelligent connected devices
should be developed using a design-forsecurity philosophy that helps harden
products against common attacks.
The philosophy includes features to
facilitate physical and logical access
control and intellectual property
(IP) preservation.
The
Rockwell
Automation
CompactLogix PACs, for instance,
are able to participate in FactoryTalk

Security services, which help verify the
identity of users attempting to access
the automation system and the types
of actions they are authorised to take.
Rockwell Software Studio5000 v20
(and later) features change detection
and logging capabilities to protect
IP and detect modifications made to
the system.
Network solutions must meet
the unique needs of industrial
automation and IT. The infrastructure
will most likely include devices that
provide secure routing and firewall
capabilities, virtual private networks
(VPNs), access control lists (ACLs)
and IPSs. Switches must also support
ACLs as well as device authentication,
unauthorised device identification
and encrypted administrative traffic.
The Stratix 5900 Services Router
from Rockwell Automation combines
several security functions into a single
appliance to protect the industrial
automation and control systems
network at the perimeter and at the
cell/zone level. The Stratix managed
switches use a leading-edge switch
architecture and feature set, along
with powerful configuration tools,
helping to provide secure integration
with the enterprise network using
tools familiar to IT professionals.
At the same time, they allow easy
setup and diagnostics from within
the Rockwell Automation Integrated
Architecture using tools familiar to
manufacturing professionals.
On the software side, applications
used in conjunction with control
systems should verify the identity
of users and help secure access to
the control system. For instance,
FactoryTalk Security from Rockwell
Automation provides user access
controls and role-based security
to controllers, HMIs and software
while
FactoryTalk
AssetCentre
tracks users actions, manages assetconfiguration files and provides
backup and recovery of operating
asset configurations.
Protecting the
Control System
There are two ways to provide
remote access to a control system,
direct and indirect. Direct access
allows an external user to establish
a secure connection directly into an
industrial automation control system
(IACS), production line or machine.
Remote users can access the system
once a VPN tunnel has been set up
to initiate communication from the
software on the computer being used
for access to the IACS.
Indirect access to an IACS provides
communication via an intermediate
remote access server (RAS) located
in the operators demilitarised zone
(DMZ), a buffer area providing a
barrier between the manufacturing
and enterprise zones while allowing
users to securely share data and
services. Once the VPN connection
has been established, the external
client uses either a thin client software
application or a web browser to set
up the connection to the RAS.
Indirect access to a control system
is the preferred access method in
a production environment, as this
approach sets up a temporary trusted
image used to access the control
system. Trusted assets can talk to the
control system, but threats are not
able to easily pass back and forth.
Challenges for
Machine Builders
Machine builders always strive
to reduce the cost of their product,
provide added value to their customers
and differentiate themselves from
their competitors. However, they also
need to protect their investments and
expertise the basis of their added
value and differentiation from
unauthorised access by third parties
and from unintentional damage by
their customers staff.
Implementing a complete defencein-depth
strategy
could
pose
challenges for machine builders.

An IACS is usually managed by the
companys production division while
enterprise access via solutions
such as VPNs is handled by the IT
organisation. Therefore, it is essential
that the machine builder collaborate
with IT and production when
implementing a security structure
that takes the companys security
policies into consideration.
In addition, system access given to
untrusted devices, such as a computer
owned by an external business
partner, exposes a production system
to viruses and malware. For example,
access to the control systems could be
based on a dial-up modem connection
that circumvents the manufacturers
firewall. This external access bypasses
the customers security perimeter and
provides back-door access via the
production system.
Use of back-door access is not
preferred, as the system is not
typically monitored and requires
more investment into security
devices to be placed at each access
point. In many cases, the machine
builders are smaller companies with
with much fewer security measures
in place; their solutions can serve as
an easier route into a system than
attacking larger customers systems
directly. In this scenario, machine

builders can potentially expose their
customers, and their own businesses,
to significant risk.
Machine
builders
have
a
responsibility to provide and/or
comply with customer security
policies. They will want to employ
product security features to enhance
IP protection and data confidentiality
and use system capabilities that
restrict access and define roles and
responsibilities.
Rockwell Automation delivers a
combination of industrial control
system design and best practices,
contemporary
technologies
and
professional services that help
manufacturers and machine builders
address risk and improve performance.
Successful
collaboration
with
strategic partners results in unique
expertise and insights that facilitate
the design and management of a more
secure connected enterprise.
Companies that establish a secure
environment will make the most
of the promise and benefits of the
Connected Enterprise including
cloud, virtualisation, mobile devices
and other emerging technologies
while protecting mission-critical
automation functions and assets. AT
13
APPLICATION STORY
Hamilton City Council Meets Compliance

Demands with System Upgrade
Rockwell Software enables water plant to improve performance efficiency and meet
regulatory compliance requirements.
he Waikato River the longest

river in New Zealand supplies
all of Hamilton citys water supply. Water is treated, distributed and
managed by the Hamilton City Council
to ensure that when water reaches consumers, it is free from harmful organisms
and meets water supply standards.
Hamiltons reticulated (piped) water
supply system consists of one water
treatment plant that provides potable
water to eight different reservoirs
located around the city through over
1,000 km of piping. The reticulated
network delivers the water straight to
the taps of consumers. Every second
of each day, Hamilton City Council
produces an average of 2,385 glasses
of high quality drinking water to over
51,000 homes and industrial premises.
The council is also responsible for
the operation of the Pukete Wastewater
Treatment Plant, which services a
region that has grown rapidly in recent
decades to have a population in excess of
150,000. Like the city, the Pukete WWTP
is continually developing, in its case to
improve operational performance and
an upgrade to their supervisory control

and data acquisition (SCADA) system
at the plant, enhancing the ability of key
stakeholders to make informed decisions,
improve performance efficiency and
meet regulatory compliance.
Efficient Compliance
After the New Zealand Ministry of
Health issued revised drinking water
standards in 2008, water treatment
facilities have had to track, save and
provide monthly reports on water
production, intake and discharge levels.
Crucially, the standards require that
water treatment plants retain operating
data for 10 years.
More than a decade ago, Rockwell
Automation provided the Hamilton
City Council with the software suite for
its previous SCADA system. However,
the RSView32 system had become
outdated over time and inefficient for
compliance with modern-day regulatory
requirements set out by the New
Zealand government.
With its previous SCADA system,
the council had often recorded data
By upgrading to the FactoryTalk suite, the key

benefits identified by council included superior
reporting for compliance to government regulations,
improved system reliability and stability, and
reduced risk when contractors are onsite to
undertake modifications or further expansions.
maintain compliance with a changing
government regulatory environment.
Leveraging
the
FactoryTalk
Integrated Production and Performance
Suite from Rockwell Automation,
Hamilton City Council implemented
14
manually before transferring this

information into Microsoft Excel
spreadsheets for reporting. A faster,
more accurate and automated reporting
system was needed, one that could
rapidly
generate
pre-determined
reports automatically for sharing with

authorised groups.
Our previous system was outdated,
and we required an upgrade to help
simplify the process of complying
with current water regulations in
New Zealand, says Gary Pitcaithly,
automation and electrical manager
at Hamilton City Council. Not
only that, he continues, but we
identified the potential for improving
operational efficiencies at the plant
by implementing an integrated system
that aims to increase productivity and
reduce downtime.
A key aim of the upgrade was to
deliver a system with the ability to retain
10 years of data in a stable and reliable
manner. At the same time, the system
would need to provide operational
efficiencies compared with the previous
operating system while also maintaining
a secure environment only accessible
by authorised stakeholders.
To improve on this process, Hamilton
City Council engaged Rockwell
Automation to provide the latest
versions of the FactoryTalk software
suite as the integral element of an
upgrade to its system.
According to Prasad Nory, industry
manager South Pacific at Rockwell
Automation, FactoryTalk Historian
and FactoryTalk VantagePoint are
increasingly becoming standards in the
water/wastewater industry, especially
with the need for compliance to
changing drinking water standards.
Also, FactoryTalk Historian ME has
been used by some councils in their
pump stations to store data locally to
take care of communication failures
and meet compliance.
By upgrading to the FactoryTalk
suite, he continues, the key benefits
identified by council included superior
reporting for compliance to government

regulations, improved system reliability
and stability, and reduced risk when
contractors are onsite to undertake
modifications or further expansions.
The FactoryTalk software suite
delivers a real-time exchange of
information throughout organisations,
a critical element that allows for more
informed business decisions, improved
responsiveness, increased productivity,
reduced costs and ease of compliance
with regulations.
Implemented in-house by Pitcaithly,
Hamilton City Council upgraded the
WWTPs system over six months to
include the FactoryTalk View (SE),
FactoryTalk Historian, FactoryTalk
VantagePoint, FactoryTalk AssetCentre
and
FactoryTalk
ViewPoint
applications. The Rockwell Automation
Customer Support and Maintenance
team provided support to the council
during the upgrade, particularly for
the migration from Historian Classic to
FactoryTalk Historian.
The long-term storage and reporting
capabilities required to comply with
water standards are provided by
FactoryTalk Historian and FactoryTalk
VantagePoint. Data is stored in the
Historian server for the required 10 year
retention period and is easily accessed
for analysis and reporting purposes.
FactoryTalk VantagePoint is used
by the plant to schedule and produce
automatically
generated
reports
providing information on periodical
water consumption, discharge, intake,
water quality and storage levels.
FactoryTalk AssetCentre provides
improved contractor control, change
management and storage capabilities.
Most importantly, the plant is now
positioned to efficiently comply with
water regulations in New Zealand,
including the storage of data and
records for 10 years.
Delivering Fresh Water and

Improved Responsiveness
The benefits of the new Integrated
Architecture solution will help the plant
supply fresh drinking water and a clean
environment to residents of Hamilton
for many years to come. According to
Pitcaithly, historical and reporting data
is now available more quickly and

accurately following implementation
of the FactoryTalk suite.
The upgrade has delivered greater
ease of use of our system throughout
the WWTP. The new Historian is
superior in how it stores data and
makes generating information for vital
reports a much more efficient task to
undertake, explains Pitcaithly.
The VantagePoint software, he
continues, allows us to develop
reports at will, whether it is for
compliance to water standards or for
other needs. These reports can then be
published as web-based reports that
are available for anyone authorised to
view them.
Another key result of the upgrade
has been the flexibility it has added
for personnel operating the system at
the WWTP.
Pitcaithly says, The FactoryTalk
software suite has enabled our team
to be more flexible with their time,
as we are now able to edit or update
reports as we go. We now simply store
our data directly into Historian, and
the data spreads directly from the
programmable automation controller
(PAC) to a human interface. This data
is incorporated into spreadsheets for
us to interrogate, whether it is on a
daily, weekly or monthly basis, to tell
us if weve had a breach in turbidity
or if chlorine levels arent what they
should be.
The flexibility extends to the ability
of system users to remotely access
the software from tablet computers or
smart phones. The team has tablets
and smart phones that can basically
access FactoryTalk View anywhere in
the world. If they are out of the office
or on-call, the system can be easily
accessed and key changes made,
concludes Pitcaithly.
With the FactoryTalk software suite
delivering new found operational
potential for the plant, the council
is planning to continue to update
and improve its system further in the
coming years in order to utilise these
capabilities. AT
15
APPLICATION STORY
Pohokura sets the standard

for remote operation and sustainability
Located off the Northern Taranaki coast, the Pohokura field is New Zealands largest
natural gas resource. To achieve zero normal operational presence (ZNOP), the
Pohokura production station implemented a new integrated automation control system
from Rockwell Automation.
atural gas is a very valuable

resource. It is an environmentally
friendly, clean fuel when
compared to other fossil fuels.
Natural gas is more efficient with 90
per cent of production reaching the
point of consumption. The efficiency
is
constantly
improving
with
technological advances in extraction,
transportation and storage techniques.
The transportation system for natural
gas consists of a complex network
of pipelines, designed to quickly and
efficiently transport natural gas from
its origin to areas of high demand.
The Pohokura field, offshore from
Taranaki, is the countrys largest
natural gas resource, owned by a
joint venture between Shell, Todd
Pohokura, and OMV New Zealand.
The production station is operated by
Shell Exploration NZ which uses the
services of Shell Todd Oil Services
(STOS). The Pohokura field natural gas
is fed into the national grid network.
The first commercial gas flowed from
three onshore extended reach drilling
wells in the Southern part of the field
in September 2006. In March 2007, gas
and condensate began to flow from
the first of five offshore wells via an
undersea pipeline back to an onshore
production station at Motunui.
Developing an unmanned site
where operations are monitored from
a control room in New Plymouth
required the combined expertise of
engineers, consultants and systems
integrators.
The Pohokura design
contractor,
Transfield
Worley,
appointed
long-standing
systems
integrator
partner
Engineering
Control Limited (ECL). One of the
requirements for remote operation
was that the motor control centres
16
(MCCs) be integrated into the main

plant control system on an intelligent
network so that the information from
the gas station could be fed back to the
control room. Transfield Worley based
the new system on the DeviceNet
to deliver the project on time, on

budget and safely, with no harm to
personnel or any adverse effects to the
neighbours or the environment.
The operational philosophy for
the Pohokura production facility
By using Shells technical expertise we set out to

deliver a highly reliable unmanned gas production
station with a small environmental footprint.
network together with the AllenBradley ControlLogix platform from
Rockwell Automation.
Another requirement was that the
status of power switchgear at the
400V MCCs and the plant 11kV main
switchboard had to be available in the
control room and this switchgear had
to be operable from the control room as
well. This was achieved by hardwiring
the switchgear to discrete I/O in the
ControlLogix. Being able to operate
the switchgear from remote is also a
welcome safety feature as it removes
the need for local operation and so
does not expose operators to possible
harm from such things as arc flash as
may occur if there is a switchgear fault
or failure whilst it is being operated.
Establishing a remote
operation
Pohokura produces over 45 per cent
of New Zealands natural gas which is
reticulated around the North Island to
industry and domestic consumption.
By using Shells technical expertise
we set out to deliver a highly reliable
unmanned gas production station with
a small environmental footprint, said
Paul Brown, Pohokura Operations
Engineer. A priority for us was
was to establish an unmanned site

with zero normal operating presence
(ZNOP); plant operation would be
performed off-site from a remote
control room in New Plymouth using
a Distributed Control System (DCS).
Remote operation is an ideal way to
help keep personnel safe and away
from potentially hazardous equipment,
but its operational success relies on
excellent control, fault diagnostics and
network capabilities.
DeviceNet provided a network
solution that could help provide
reliable communication and also
had the added feature of Automatic
Device Replacement (ADR), allowing
for reduced downtime with automatic
download of device parameters,
said Prasad Nory, Industry Manager,
Rockwell Automation. ADR consists
of configuration and auto-address
recovery which effectively lowers
maintenance requirements. Operating
24 hours a day, 7 days a week, Pohokura
has a scheduled proactive maintenance
day every month to identify and deal
with potential problems. .
The Pohokura blueprint

The Transfield Worley electrically
engineered design was the basis for
a completely integrated solution

that required the capabilities
of leading board builders,
Switchbuild Ltd. The Pohokura
solution evolved around the
development of two low-voltage
MCCs. Two 2.5MVA transformers
feed into the first low-voltage MCC
via 4000A Air Circuit Breakers
(ACBs). Power from the first MCC
is then fed through to the second
low voltage MCC. The intelligent
MCC design utilised the DeviceNet
network, communicating to the
DOL start motor starters for
control and monitoring. The E3
plus smart overloads provided
motor protection that very closely
matched the motor operating
characteristics with the enhanced
protection capabilities such as
earth fault, stall, thermistor and
loss of load that are normally
provided by much more expensive Pohokura field is New Zealands largest natural gas resource
motor protective relays.
An Allen Bradley ControlLogix
treatment systems, an absorbent
Programmable Automation Controller Environmental excellence
is used to provide the comprehensive
The implementation of state-of- skimmer removes residual floating
monitoring and control of the MCCs the-art engineering has enabled hydrocarbons. Stormwater is further
and feeds back information to the the Pohokura plant to be operated processed via a specially designed
distributed control system. The Allen remotely. Safety to personnel and wetland where plants are utilised as
Bradley solution provides advance the environment take an even higher a natural bio-filter. Filtration through
load protection. The client has the priority in a remote operation so the wetlands removes any residual
ability to analyse the performance plant and components must work hydrocarbons. These environmental
of their motors and view faults, all in reliably with minimal maintenance. features resulted in Shell Pohokura
an integral unit that is visible from All components chosen for the receiving a sustainable development
the distributed control system, said Pohokura project had to have and technical innovation award from
Donald Liddell, Manager, Switchbuild. proven reliability, said Paul Brown, the Taranaki Regional Council in 2010.
Reaction
to
the
integrated
To avoid costly downtime at Pohokura Operations Engineer.
Pohokura, ECL developed and
To
achieve
environmental automation control solution from
incorporated switching Controls in excellence,
modifications
were Rockwell Automation has been
the PAC in the event that power is lost made to the original design of the positive. There have been no
from one of the two 11kV incomers. field. Horizontal directional drilling problems with the PACs from
According to Peter Huitema, Engineer technology was used to eliminate Rockwell Automation in the five
ECL, Normally when supplies switch the need to have a pipeline from the years of Pohokura operation
over you lose power, even if its onshore production station out to the our objectives have been fully
just a few milliseconds, the motors offshore platform that would have satisfied in terms of budget, timing,
will shutdown. To avoid this, we run over the cliff face and across the personnel safety and environmental
determined how many seconds the foreshore. Insteadand as a first for sustainability, concludes Brown. The
motor can be with no power without New Zealanda pipeline was inserted value of the successfully operating
causing any damage. We used inertia behind the cliff face and underneath remote control operation at Pohokura
to keep motors running for up to 1.5 the foreshore, so there was no visible has been realised and as such, is
seconds, to allow time for the other or physical intrusion and the local currently undergoing an expansion
to create another plant using the
supply to switch over. By programming coastal environment was preserved.
this information into the Control
The plants processing areas are same easily extendable solution
System we were able to avoid costly built in concrete bunds. Before the provided by the Rockwell Automation
shutdowns.
water is drained into the stormwater Integrated Architecture system.
17
OEM INNOVATIONS
Machine Builders Improve Equipment Performance

Rockwell Automation helps OEMs customise their machines.
ustomers of machine builders

demand solutions that increase
business agility, optimise productivity and achieve sustainable
objectives while lowering the total
cost of ownership. Machine builders,
therefore, must differentiate themselves
amid global competition and rapidly
evolving technology while meeting customers needs.
Original equipment manufacturers
(OEMs)
Guangdong
Yeudong
Mechanical Industry Co. Ltd. and
Hoong-A Corporation have done just
that. The companies have teamed
with Rockwell Automation on the
design of their respective machines,
resulting in products that have reduced
programming, minimised installation
and startup time, and simplified repair
and maintenance.
The Guangdong Yuedong Mechanical
Industry Co., Ltd., headquartered in
Shantou City in Chinas Guangdong
province, designs machinery for the
food, beverage, dairy and packaging
industries. The company sells its
products in more than 20 Chinese
provinces and exports them to over
70 countries and regions including the
Americas, Europe, Southeast Asia and
the Middle East.
The companys CSL-C30 Gable Top
Packaging Machine is driven by an
Allen-Bradley PowerFlex 40 AC drive
with an attached single-turn absolute
encoder. With each complete turn
of the motor, a packet of product is
produced. All servo drives synchronise
with the main motor in a master/slave
relationship, and all axes use compact
MP-Series low-inertia servo motors.
A Rockwell Automation Kinetix
Integrated Motion System controls
motion for the in-feed conveyor, turret
indexer, main conveyor, servo filler and
servo lifter.
The single-lane machine has a
single-servo filling head. Its bottom-up
filling system regulates flow to reduce
18
turbulence and prevent foam. A servocontrol carton lifter syncronises with

the product fill-flow rate.
The CSL-C30 is controlled by a
Rockwell Automation CompactLogix
programmable automation controller
(PAC), a Kinetix Integrated Motion
System and RSLogix 5000 programming
software. The controller carries out
discrete, drive and integrated motion
control. It sequentially controls the
packaging machine and, through SERCOS
interfaces, integrates with a Kinetix 6000
system for multiple axis control.
The RSLogix 5000 softwares integrated
motion instruction set eliminates the
need to write and coordinate two
programs on different controllers. It also
simplifies the application programming
and enhances system performance.
Hoong-A Corporation, South Korea,
makes
packaging
machinery
for
pharmaceutical and non-pharmaceutical
use. In order to meet the specific needs
of each client, the company custombuilds machines, including its smartline
product for small- and medium-sized
batch production. The machine features
a balcony-style structure with a highly
accurate web transport system for
pharmaceutical blister packaging in
thermoforming and cold forming. Key
elements include the HM 300P blister and
HC 200 cartoner, which deliver an output
of 300 blisters and 200 cartons per minute.
The blister machine is configured
around an Allen-Bradley CompactLogix

5370 L36ERM PAC, Kinetix 5500 servo
drive and the Stratix 2000 unmanaged
network switch for the Device Level
Ring (DLR) topology. A PanelView
Plus 6.0 HMI graphic terminal is used
for smarter machine control and
effective operation.
The Kinetix 5500 connects to and
operates with the CompactLogix 5370
PAC, supporting Integrated Motion on
EtherNet/IP. The drive helps minimise
machine footprint and simplifies
system wiring.
The control system for the HC 200
cartoner is based on the CompactLogix
5370 PAC, Kinetix 5500 servo drive for
1-axis motion and Kinetix 350 singleaxis EtherNet/IP servo drive. Leveraging
a single network, EtherNet/IP simplifies
the integration of the system including
HMI, PAC, I/O and motion.
These innovative machines from
Guangdong
Yeudong
Mechanical
Industry Co. Ltd. and Hoong-A
Corporation help these companies lower
their Total Cost to Design, Develop and
Deliver products. More importantly,
the machines help their customers
to operate with greater speed and
accuracy and shortened lead times.
For more information about OEM
solutions, visit:
www.rockwellautomation.com/
rockwellautomation/solutions-services/
oem/overview.page?. AT
$19 trillion
reasons why you need to know

the power of Internet Protocol
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BILLION
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1.3
zeTaByTes
Global IP traffic
by 2016
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TRILLION
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Private sector value at stake

from Internet of Things
$3.8
BILLION
TRILLION
extra customers with

improved experience
Value at stake from

manufacturing
Get IP. Get the advantage

Get the power of standard, unmodified Internet Protocol (IP) working for you,
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Providing expert guidance, detailed information and acknowledged best practice,
Industrial IP Advantage helps you to unlock the potential in todays communications
technologies. This enables you to improve performance and reduce costs.
Get online to learn more.
www.industrial-ip.org
PARTNER FOCUS
System integrators are invaluable to our business: Rockwell Automation

Rockwell Automation continues to deliver an industry leading System Integrator program built on the three pillars of trust, collaboration and value
In an increasingly competitive global

marketplace, leveraging technology to
help sustain profitable business growth
is a focus for many companies.
According to Darryl Kaufmann,
market access manager for Australia and
New Zealand at Rockwell Automation,
Our System Integrator program is based
on a pro-active relationship between
Rockwell Automation, our distributor
and the System Integrator. This unique
relationship helps drive strategy as
well as a technical understanding of
our solutions and should assist the
System Integrator solving production
challenges. Furthermore, the System
Integrator has better access to our
entire PartnerNetwork including our
Encompass Partners.
The program offers system integrators
the chance to continually enhance
competencies and capabilities across
multiple disciplines including, control,
process, information, and safety.
The Recognised System Integrators
are resources that are best positioned to
reduce project risk when leveraging our
technologies. Solution Partners possess

those same traits, but they differentiate
themselves with a capability that is
unique and specialised, with the ability
to deliver across a broad geography.
In return, we offer our Recognised
System Integrators and Solutions
Partners the opportunity to increase
market awareness, expand into new
market sectors and improve technical
competency and functional excellence.
We work closely together with shared
commitment and behaviours for
customer success, said Kaufmann.
Rockwell Automation develops
proactive and mutually strategic
relationships with system integrators
and acknowledges that integrators play
a particularly important role in the
Australian and New Zealand region.
According to Mauro DelleMonache,
marketing director at Rockwell
Automation, In other locations with
larger volumes, system integrators tend
to develop a more specific industry or
application expertise but in our region
system integrators tend to work in a
We have a long history of partnering. It is

fundamental in our DNA. We see it as the
best way to address customer needs.
Our approach to partnering is based on
an understanding that no single supplier
can do it all and a belief in the importance
of working with best of breed companies
to bring innovation, global reach and local
responsiveness
Keith Nosbusch
Chairman and CEO, Rockwell Automation
variety of different industries.
Our architecture is a framework
of technology that is most useful
when an integrator has applied their
methodologies and engineering to make
the product of value to the customer.
Integrators are absolutely vital.
Without a successful integration
network we would not be successful
in Australia and New Zealand, said
DelleMonache. AT
Our partners, your success.

Distinguished system integrators who know your business.
Solution Partners and System Integrators, as part of our PartnerNetwork, offer differentiated skills and experience in the
areas of control, process, power and information. They can help design, implement, manage and maintain your automated
systems and keep your facilities operating at optimum efficiency.
Put our advanced technologies together with the expertise of our Solution Partners, and you have a unique
resource to call on.
For more information, go to:
www.rockwellautomation.com/go/tjsi
PartnerNetwork is a registered trademark of Rockwell Automation, Inc. Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.
PRODUCT FOCUS
HIPERFACE-to-DSL
Converter Kit
The new Allen-Bradley Kinetix 5500 servo drive converter is designed
to convert HIPERFACE feedback to DSL.
With the new converter, users have the flexibility to use a variety of
motors with their Kinetix 5500 drive, including any of the HIPERFACE
feedback Allen-Bradley MP-Series motors and actuators MP-Series low
inertia, MP-Series stainless steel, MP-Series food grade and MP-Series
medium-inertia rotary motors as well as the MPAR, MPAI, MPAS and MPMA
linear motors.
The converter kit is powered
by the drive, which means there
is no external power supply. This
eliminates parts and installation
time. It attaches directly to
the drives DSL feedback port,
simplifying installations. In
addition, motor configuration
and selection are the same as
existing Allen-Bradley Integrated
Motion with EtherNet/IP servo
products, translating into ease
of use.
http://literature.rockwellautomation.com/idc/groups/
literature/
documents/in/2198-in006_-en-p~a1.pdf
Next-Generation Motor Control

The Allen-Bradley E300 Electronic Overload Relay integrates
communications, including EtherNet/IP, patented current-measurement
technology and I/O options. The modular design featuring wide current
range, multiple sensing capabilities, expansion I/O and operator interface
provides flexibility to tailor the device to user needs.
The relay monitors motor performance, providing diagnostic information
on voltage, current and energy; trip/warning histories; percentage thermal
capacity utilisation; and time to trip/reset. Operational hours, number
of starts and snapshot log are also monitored. In addition, the relay has
incorporated the newest technologies directly
into the device to help simplify installation and
configuration.
A dual-point EtherNet/IP option allows
relays to be daisy-chained and eliminates
the need for an Ethernet switch.
Maintenance personnel can integrate the
relay from any Internet-enabled device
via a Web browser without the need for
special software. The relay supports a DLR
network topology to maintain uptime.
Universal Disconnect Switch

Simplifies
Design
The newAllen-Bradley Bulletin
1494U visible-blade disconnect
switchprovides capabilities for
applications with 30, 60 and 100
amps. Rockwell Automation
will be rounding out the Bulletin
1494U line in the next year, with
ratings up to 600 amps. The
Bulletin 1494U visible-blade
disconnect switch provides visible
confirmation that the switch is
in the on or off position as it
isolates motors, motor controllers
and other loads from a supply
circuit. The switch offers flexibility covering all applications, thereby
reducing needed inventory. Users can choose from a number of styles and
options to meet their specific application needs, including nonfusible or
fusible versions, and the fusible version provides short-circuit protection.
http://ab.rockwellautomation.com/Circuit-and-Load-Protection/Disconnect-Switches/Visible-Blade/1494U-Universal-Disconnect-Switches
Integrated Display Computers

with horsepower
The Allen-Bradley 6181 Integrated Display Computer form a dynamic
portfolio, with Standard, Performance and Advanced Models that provide
all-in-one industrial PC options to help meet your application needs. The 6181
models offer an open computing platform with plenty of horsepower to run
most client, station and even virtualised software architectures. While the
Standard models maintain their original characteristics, the latest generation
Performance models build upon the trusted Series E 6181 Integrated Display
Computer platform to help provide you with an enhanced user experience and
exceptional processing power.
http://ab.rockwellautomation.com/computers/integrated-display-computers/bulletin-6181
http://ab.rockwellautomation.com/circuitand-load-protection/lv-motor-protectors/e300overload-relays
21
PRODUCT FOCUS
The Kinetix 5500 and VPF Low Inertia Motor Deliver High
Performance and Scalability
Rockwell Automation has expanded its Integrated Architecture system with the Kinetix 5500 servo drive with Integrated Safety option and VPF Low Inertia
servo motor offering. The system is designed to meet the unique needs of many food and beverage applications
The Kinetix VPF Motor connects to Kinetix 5500 drives for simple, optimised motor/drive operation. It adds 63 mm and 75 mm frames to MPFs available
100/115/130/165 mm frame sizes. It has the same dimensions as the VPL motors for same frame/stack selection.
The motor features food grade, improved white paint; single cable; non-corrosive food grade fasteners and shaft; and food grade shaft seal and grease. It is
also REACH and RoHS-compliant.
Platform options include optional lower speed windings, allowing for optimised system sizing and costs; holding brake/non-brake; and multi-turn/singleturn feedback.
The servo drive and motor reduce system cost and inventory. Whats more, the
combination is energy-efficient, providing up to 50 percent less energy usage with
proper system sizing. In addition, lower speed windings allow for lower current, a
smaller drive and smaller gauge cables. Furthermore, the system minimises installation
errors with a well-shielded cable clamp design and simplifies mounting, as there is no
backplane or power rail required.
http://ab.rockwellautomation.com/motion-control/kinetix-5500-servo-drive
Make more use of the data you

already collect
Software Drives Automation

Productivity
The new FactoryTalk VantagePoint EMI software offers real-time

production information in a dashboard, trend, report, or key performance
indicator (KPI) on a mobile device or computer web browser. Now decision
makers can be notified when production parameters move outside their
pre-set limits. This enables informed decisions, utilising real-time data, on
mobile devices or desktops to become a standard process in your improved
operations. Preparing simple reports no longer requires hours or days spent
collecting relevant data from disparate systems, which then must be routed
and analysed before production decisions can be made.
Only FactoryTalk VantagePoint EMI organises, correlates, and
normalises disparate data from your manufacturing and production
processes and business systems in a Unified Production Model (UPM). It then
enables you to organise and present information in everyday language
tailored to users needs on mobile devices or desktops.
FactoryTalk VantagePoint EMI helps solve many of the delays associated
with typical manufacturing reporting. By organizing all data sources in a
Unified Production Model, bridges are created between multiple systems,
vendors and data types. Data in the model can be accessed from anywhere,
by anyone in real world terminology. This data can then be presented as
information relevant
to the users role and
responsibility within the
organisation.
With theRockwell Software Studio 5000 Logix Designer v24

softwareengineers have new design capabilities that can dramatically
increase automation productivity, improve start-up time and reduce costs
throughout a projects life cycle. Latest additions include an applicationcentric view of code, enhanced work flows for more efficient re-use of
content, and new collaborative tools that make it easier for multiple people
to work together.
The Studio 5000 Logix
Designer v24 software is used
to configure Allen-Bradley
Logix5000 controllers, for
discrete, process, batch,
motion, safety and drive
control.
In addition, the Studio
5000 Logix Designer v24
software supports the AllenBradley Kinetix 5500 servo
drive with integrated safety
to help machine builders
reduce development and installation time. It also provides support that
allows the Allen-Bradley PowerFlex 527 AC drive to be the first variable
frequency drive to exclusively use the motion instruction sets within the
Studio 5000 Logix Designer v24 software for machine control and motor
synchronisation.
For more information,

visit:
http://www.rockwellautomation.com/rockwellsoftware/products/
factorytalk-vantagepoint.
page
22

http://www.rockwellautomation.com/rockwellsoftware/products/
studio5000-logix-designer.page?utm_source=Marketing&utm_
medium=PublicRelations&utm_content=Studio5000_NewsRelease_
November182014&utm_campaign=IA_NA_XX_English_2015
NEWS/CALENDAR
Auto-Bakes international success recognised by Manufacturing Export

Awards
Auto-Bake is delighted to announce
that it has been Highly Commended
for manufacturing excellence in
the Manufacturing Export Awards
category of the Premiers NSW Export
Award.
The Premiers NSW Export Awards
aims to recognise excellence in the
export of goods and services by NSW
business. The Awards acknowledge
the important contribution of
businesses to the economy through
job creation and increased prosperity
for the community and for the state.
Auto-Bake is a global designer and
supplier of fully automated industrial
baking ovens and systems.The
company has been a commercial
baking innovator for more than fifty
years delivering customised, fully
automated production lines that are
renowned all over the world.
Founded in Australia, Auto-Bake has
now become a truly global operation,
servicing North America, Europe, Asia
and the Middle East.
According to Amanda Hicks, CEO at
Auto-Bake, This award acknowledges
the contribution of our wonderfully
talented team whom have built our
companys reputation by providing
unique solutions to the worlds largest
food producers.
More broadly we recognise that
this success can only be sustained

if the innovation momentum is
maintained. Therefore in addition
to our own resources we ensure that
we are aligned with and integrate
the latest development from our
key suppliers such as Rockwell
Automation to ensure we can meet
the new opportunities wherever they
arise, said Hicks.
As a Rockwell Automation Machine
Builder Partner, Auto-Bakes worldrenowned products utilise the
companys industry leading industrial
automation technology. Auto-Bake
provides not only the baking system
or hardware but also the software and
installation support. The company
has adapted its unique Serpentine
technology to meet the needs of
the worlds major food
manufacturers.
According to Jacqueline
Las Pinas, account
manager at Rockwell
Automation, We are proud
to be associated with
Auto-Bake because they
are an innovative company
that incorporates the latest
technology advances in
their products.
At Rockwell
Automation we are
committed to delivering products

and solutions to help Auto-Bake
achieve machine control excellence.
Through our global presence we
are able to work with Auto-Bake to
extend superior service and support to
customers worldwide, she said.
About Auto-Bake
Auto-Bake is a global designer and

supplier of ovens and baking systems.
Based on the companys innovative
Serpentine baking technology,
Auto-Bake continuous baking systems
are custom-designed to meet the
needs of a diverse range of baking
applications, including the production
of cakes, muffins, cookies/biscuits,
pies, desserts, and bread and proofed
products.
VISIT ROCKWELL AUTOMATION AT THESE EVENTS: FEBRUARY APRIL 2015

DATE
EVENT
LOCATION
23
Integrated Architecture Tools:

EtherNet/IP Capacity Tool
The EtherNet/IP Capacity Tool can help you in the initial layout of your EtherNet/IP
network by calculating resources (nodes and packets per second) used by a network.
This allows you to determine the feasibility of your network in just a few minutes.
Download this software utility from the Integrated Architecture Tools web site to assist
with the design of your next project.
The EtherNet/IP Capacity tool are available

on the IA Tools site: www.ab.com/go/iatools
Integrated Architecture is a trademark of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA.
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. AD2014-48-EN

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Automation

Australia & New Zealand

Networks vs. Protocols

Making the Move to

he Connected Enterprise information-driven business

Real-time information brings the ability to sense

3 News & Events

Rockwell Automation developments

News and events from around

6 Cover Story The

Security is a key element in enabling

10 Networks vs. Protocols:

EtherNet/IP uses the tools and technologies

12 Protect Machines with

The defence-in-depth concept identifies

Rockwell Software enables water plant

Pohokura production station sets

Rockwell Automation helps OEMs

Recent additions to the Rockwell Automation

Automation Today is published by

Tom OReilly, President | Rockwell Automation, Asia Pacific Region

EtherNet/IP is a trademark of the ODVA.

January 2015 AUTOMATION TODAY ASIA PACIFIC

NEWS & EVENTS

Dalian Software R&D

ockwell Automation recently celebrated the

Ethisphere Institute Honors Rockwell

FIRST Robotics brings Regional event down under in 2015

Robot mania is set to hit Sydney as

In this event, teams will have about

mentor-based programs that build

Automation University is coming to a town near you

January 2015 AUTOMATION TODAY ASIA PACIFIC

of insight, vision, ideas and practical

opportunity to learn by experience

AUSTRALIA & NEW ZEALAND

Rockwell Automation and Cisco deliver networking technologies training

Technologies (IMINS). This is a

to helping customers succeed and

can help customers lay a foundation

offering from Rockwell Automation.

AUTOMATION TODAY ASIA PACIFIC January 2015

Security is a key element in enabling manufacturers to leverage the

stablishing a Connected Enterprise

When we speak to our customers

LEARN MORE ABOUT

isit these resources to learn

Video: Rockwell Automation

January 2015 AUTOMATION TODAY ASIA PACIFIC

Free White Paper:

That value opportunity comes

next 10 years in the IoT. That value,

Security at the Forefront

a firewall. You have to be aware of the

cyber-security personnel and viceversa to cross-educate their strengths

Bringing the Cloud

ockwell Automation and its

Cisco and Rockwell Automation

AUTOMATION TODAY ASIA PACIFIC January 2015

s organisations seek greater

1. Control who has network

January 2015 AUTOMATION TODAY ASIA PACIFIC

it all, says Keith McPherson, market