industrial ethernet,part 2: case studies

Industrial Ethernet,Part 2: Case Studies

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Purpose and Learning Objectives

Attendees will learn:• The importance of correct cable installation and

verification• Reasons why should you spend time designing

your Ethernet Infrastructure• How to minimize the impact of an existing

poorly-designed network Infrastructure.• Key market trends about industrial Ethernet.

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Speakers

• Steve Schneebeli, Director of Engineering / IT Malisko Engineering Inc.www.malisko.com

• Moderator: Mark T. Hoske, Content Manager, Control Engineering, CFE Media, covering industrial networking, among other topics, since 1994 www.controleng.com

http://www.malisko.com/

http://www.controleng.com/

Industrial Ethernet, Part 2: Case Studies

Steve SchneebeliDirector of Engineering / IT

Malisko Engineering Inc.

Agenda – Industrial Ethernet case studies

• Case Study #1 – Importance of correct cable installation & verification

• Case Study #2 – Why you should spend time designing your Ethernet infrastructure

• Case Study #3 – How to minimize the impact of an existing poorly designed network.

• Questions? (You can submit these as we go.)

Case Study #1

The Importance of Correct Cable Installation and Verification

Case Study #1 (Cont.)

How many people have seen these types of installation techniques?


• On one particular project, the client decided to install Ethernet cabling using in-house resources.

• We stressed the importance of knowledgeable installation techniques, using certified installers, following industry standards, and performing cable verification after installation.


• Our client decided to stick with their maintenance people as installers.

• One result was CAT6 cables being pulled through conduits using techniques an electrician would use for pulling larger conductor cabling.


• This installation method caused:– Kinks in the CAT6 cable, – Stretching of the internal conductors and

conductor pair twisting, – Compression of the cable.


• The non-trained client’s maintenance personnel terminated all RJ-45 plugs, which resulted in:– CAT6 cable sheaths cut too long,– Cuts into individual conductors from cutting

back the cable sheath,– Poorly and inconsistently crimped

connectors.


• CAT6 non-shielded network cabling was run within the motor control center, next to 480 V ac VFD and 120 V ac motor starter wiring. This can cause:– Electromagnetic interference (EMI)

resulting in potential interference with Ethernet cabling.


• During start-up, we noticed some issues with the 2 new Ethernet enabled MCC sections and the existing MCC sections that were retrofitted with Ethernet.

• MCCs would randomly drop out of the system tree in the PLC, along with random dropouts of HMI communications.

• We knew the majority of the new cabling was pulled through the MCCs.

• By pulling out the connection to the MCC, everything started working.


• We then started checking newly pull cables and found issues as previously outlined.

• The biggest cause of the random communications issues were RJ-45 connections.

• Several needed to be re-terminated.


• After re-terminating several RJ-45 connectors, checking for severe cable damage during pulling, and re-routing some cabling through the MCCs, communications were then solid.


• Lessons we learned from this installation is to ensure the cable installer knows industrial Ethernet network best practices, and at a minimum, tests the installation using an Ethernet cable tester prior to start-up.

Case Study #2

Reasons Why You Should Spend Time Designing your Ethernet Infrastructure


• Spending time designing your Ethernet infrastructure is sometimes overlooked.

• By spending the correct amount of time designing and specifying your Ethernet Infrastructure, you can eliminate common problems, and ensure that your network can handle future growth.


The following common questions are sometimes overlooked during a

network design.


• Managed vs. unmanaged switches – Why should I care?

• Layer 3 vs. Layer 2 switches – When do I need Layer 3?

• Port settings – Auto negotiate vs. hard coding speed and duplex

• Cheap consumer grade vs. commercial or industrial grade components – Why does it matter?


• Managed vs. unmanaged switches – why should I care?– Unmanaged switches typically do not have

any web-based interfaces to adjust port settings.

– Advanced switching technologies, such as Spanning Tree Protocol or IGMP Snooping, are only available in managed switches. (IGMP stands for Internet group management protocol.)


• Managed vs. unmanaged switches – why should I care?– Spanning Tree Protocol (STP) provides

path redundancy in the network.– STP provides redundant paths while

preventing loops that are created by multiple active paths between switches.


• Managed vs. unmanaged switches – why should I care?– Managed switches have SNMP (Simple

Network Management Protocol) built-in to remotely monitor switches on the network.

– Quality of Service (QoS) prioritizes critical traffic (such as video) within managed switches.


• Managed vs. unmanaged switches – why should I care?– Managed switches have the ability to

create VLANs or Virtual Networks. VLANs (virtual local area networks) allow a switch to logically group devices together to isolate traffic between these groups even when the traffic is passing over the same physical switch.


Sample VLAN Network


• Layer 3 vs. Layer 2 Switches – When do I need Layer 3?– Layer 2 networks forward all traffic, especially ARP

(address resolution protocol) and DHCP (dynamic host configuration protocol) broadcasts.

– Layer 3 switching can contain broadcast traffic to the local network.

– Layer 3 switches allow for routing between subnets.– Downside of Layer 3 is a decrease of switching

performance due to the overhead needed for routing.


• Port Settings – Auto negotiate vs hard coding speed and duplex– Managed switches allow for the ability to

set network speed (10 Mbps, 100 Mbps, 1 Gbps) and port duplex (half or full).

– Some applications and network devices recommend hard coding these settings on the switch to match the hard coded setting of the device.


• Port settings – Auto negotiate vs hard coding speed and duplex– When hard coding a port, care must be

taken that the settings for the port match the settings hard coded in the device.

– Communications issues will arise if both the port and the device do not match.


• Cheap consumer grade vs. commercial or industrial grade components – Why does it matter?– Saving cost of an installation makes it

appealing to use consumer grade devices.– These devices do not have the robustness

typically found in commercial or industrial grade devices.


• Cheap consumer grade vs. commercial or industrial grade components – Why does it matter?– Most consumer grade devices, such as

wireless access points and routers, do not have the range, throughput, or security features (RADIUS Authentication) of commercial or industrial grade devices. RADIUS stands for remote authentication dial in user service.


• Cheap consumer grade vs. commercial or industrial grade components – Why does it matter?– Consumer grade devices typically do not

include the ability to implement VLANS or Virtual LAN segregation.


• Lessons learned executing several industrial Ethernet network designs is:– Always make sure your are following

industry standards,– Ask yourself if you need Layer 3 hardware,– Use the right equipment for the job. Don’t

sacrifice robustness for cost savings,– Check your port settings!

Case Study #3

How to Minimize the Impact of an Existing Poorly-Designed Network Infrastructure


• When installing or upgrading an Ethernet Infrastructure in an existing plant, there is a possibility you may run into some “not so elegant” installations.

• One of our projects was to add a new process center into an existing facility, which had a very primitive controls network.


• During our first on-site visit, we took an inventory of all the switches and network devices on the existing network.

• Our client had a network device list with IP addresses, but not a good cabling diagram.

• We would need to tie our new controls network into the existing process network.


• Once the plant was down for installation of the new network, we were able to trace out connections within the existing network.

• We found switches buried in panels up in the ceiling that no one knew of.

• Cabling issues were also uncovered.


• We then began to systematically disconnect existing cabling to come up with a rough map of the network, and document connections on the existing switches.

• We replaced consumer-grade switches with industrial-rated switches.


• RJ-45 connectors were reviewed and reinstalled as needed, then checked with a cable verifier.

• We found a switch loop that was causing intermittent drop outs of PLC to PLC communications from the new system to the existing process network.


• IGMP Snooping was enabled on existing managed switches.

• All network drops on the new system were verified with a cable tester.


• By systematically reviewing each connection point in the existing process network, we were able to ensure solid communications between the existing devices and the new process system.


• Lessons learned while dealing with an existing network infrastructure:– Make sure you spend time reviewing the

physical installation and hardware,– Check existing cabling and connections,– Make sure the existing hardware is configured

correctly,– Test the network before connecting your new

system into it.

Wrap-upThese three case studies give an insight to common situations found in the Industrial Ethernet Network world, and how to remediate them.

By following industry standards, such as ANSI/TIA-1005 – M.I.C.E. and ANSI/TIA-569-C.0 (cable lengths), you can eliminate many issues found in typical industrial installations.www.tiaonline.org/standards

http://www.tiaonline.org/standards

Ethernet research and trends

Mark T. Hoske, Content Manager, Control Engineering, CFE Media

Ethernet research includesInformation from IHS on:• Use of routers versus managed switches• Pace of fieldbus connections compared to industrial Ethernet connections over the next 10 to 15 years• Use of Ethernet as an industrial communications technology in motion control • Industrial Ethernet nodes in process industries through 2016

ARC Advisory Group on outlook for industrial Ethernet switches and what is driving the marketplace

Industrial Ethernet switches, routers

Industrial Ethernet components

Ethernet is gaining on fieldbus

Ethernet growth for motion controlUse of Ethernet with motor drives and motion controllers will more than triple in 2016 from 1.8 million new connected nodes in 2011, IHS said.

Ethernet for process industriesUse of Ethernet as an industrial communications technology in motion control to more than triple by 2016, IHS said.

Ethernet switches get a boost• Use of industrial Ethernet (IE) switches, driven by discrete automation, will get a boost from increased use in process and infrastructure applications, said ARC Advisory Group in May 2013.• IE differs from commercial switches: ruggedized enclosures, high IP ratings, mounting and connector types, ability to withstand extended temperature ranges, redundant components, and conformance to industrial infrastructure standards, among others. • Infrastructure applications include smart grid and intelligent rail. • The mix of form factors, point counts, port speeds, media types, and other device characteristics continues to expand.• Availability of switches that meet requirements such as IEC 61850-3 for substation automation and EN 50155 for rail further enhances Ethernet’s suitability in infrastructure applications.

Ethernet research from others• IHS commented recently on decline in growth of stand-alone industrial routers, as use of managed switches is expected to grow steadily over five years.• While annual fieldbus connections still outpace industrial Ethernet connections, IHS believes that within 10 to 15 years industrial Ethernet will be the dominant networking technology in industrial environments and almost all components will offer Ethernet connectivity as standard. • Use of Ethernet as an industrial communications technology in motion control will more than triple by 2016, IHS said.• Industrial Ethernet nodes in process industries are projected to rise to 8.7 million units in 2016, up a 96% from 4.4 million in 2011, IHS said.• Industrial Ethernet switches, driving by discrete automation, will get a boost from increased use in process and infrastructure applications, said ARC Advisory Group.

Submitting Questions, Exit Survey and Archive Question?Type your question in the “Ask a Question” box on the Webcast console andclick “Send.” We will get to as many questions as we have time for. Questionsthat are for today’s presenters will be answered verbally during the Q&Asession at the end of the webcast.

Exit Survey:Please take a moment to answer a few questions on our exit survey that will pop up on your screen at the conclusion of thewebcast. We use the answers to help make improvements to our webcast program.

Archive:• Within 7 days, an archive with Q&A will be posted• We will send an email to registered attendees with hyperlink• Can also access from www.controleng.com home page


Speakers

• Steve Schneebeli, Director of Engineering / IT Malisko Engineering, Incwww.malisko.com

• Moderator: Mark T. Hoske, Content Manager, Control Engineering, CFE Media, covering industrial networking, among other topics, since 1994 www.controleng.com

http://www.malisko.com/


Thanks to Today’s Webcast Sponsors

Industrial Ethernet,Part 2: Case Studies

Sponsored by: