How to Build an Industrial Network

Jim Montague Control Engineering October 1, 2000

Its not easy, but its not impossible either. Users must clearly define applications needs, environments, and goals;
create precise specifications; and demand that vendors prove products can perform now and expand in the future.
So you want to build a network? Good luck and try not to panic. These days simply defining an industrial
network is difficult, so its no wonder the idea of building one may seem impossible. Traditional point-topoint analog, 4-20 mA, and other hardwired networks have been joined in the past decade by dozens of
competing fieldbus protocols, hundreds of suppliers, and thousands of related productsall claiming to
be the best solution and all sounding eerily similar. Now, Ethernet-related protocols and the advent of
embedded and wireless networking technologies are only making this situation noisier.
'This is why trying to build a network can be a lot like do-it-yourself brain surgery,' says Dick Caro, vp,
ARC Advisory Group (Dedham, Mass.).
Bob Chappel, president, Advanced Integration Group (AIG, Lawrence, Pa.), a system integrator, explains,
'Most networks look the same until you get down into them, and try to make them work and play together.
Then you find out what works together and what doesnt. For instance, we recently had a user with an
OPC client server that did interface with a second vendors HMI using 100 tags, but then it really bogged
down when it got up to 2,000 to 6,000 tags, and so we had to recreate the server client link. For awhile,
we had two vendors pointing fingers at each other, and it was up to us to prove which was working and
which had the problem.'
Due to this confusion, more engineers undoubtedly cling to
Network builders aid refiner
the saying, 'If it aint broke, dont fix it,' than might, if changing
expansion
didnt seem so unapproachable. This is unfortunate, because
A team from GE Cisco Industrial
many applications and companies desperately need the
Networks (Charlottesville, Va.) recently
savings and efficiencies that new industrial networks can
analyzed Cenex Harvest States
deliver.
Montana-based cooperative oil refinery
'Not only can a fieldbus-based network save weeks or months network, especially one 300-mile
in installation and debugging time, it also generates savings
pipeline, to help the company increase
by allowing production to begin weeks earlier, and users
capacity and provide scalability for
should take this into account too,' says Mark Stremmel,
future growth. Cenex needed to reduce
president, Device Bus Integration Inc. (Harrisburg, Pa.), a
traffic and improve bandwidth on its
system integrator.
Ethernet fiber-optic pipeline network.
The team found the existing network
Know thy application
was based on one flat-collision domain,
If building the best network ends with installing the most
which spread traffic among all devices,
appropriate system, then it obviously starts with finding that
and recommended migrating to a
system. This is obvious on the surface, but many control and
switched network architecture, which
automation experts, system integrators, and suppliers report
separated Cenexs supervisory control
that users often dont know enough about their applications
and data acquisition and corporate
and what they need to accomplish their goals. Some users
networks onto distinct virtual local area
even shop for capabilities their existing system already can
networks, allowing communication
perform.
where required.
Consequently, experts and integrators say users must
thoroughly examine and account for their existing applications, This solution used Cenexs existing
fiber backbone, but replaced standard
capabilities, and operating environments. They must describe
their existing network, determine its capabilities and operating repeater devices with smart network
switches to create individual collision
parameters, and evaluate its ability to integrate with newer
domains, limit traffic, and enable
systems. This will help users define exactly what tasks they
Cenexs subsequent 70% increase in
want their new network to accomplishprobably the most
capacity.
important step in building a networkbecause its the
foundation for clear specifications, intelligent purchasing, beneficial vendor relationship, and finally
securing the most efficient network for the least cost.
'We initially pull back from the technology, and try to determine our end-users business motivations. What
are they trying to do? Increase production? Gather more data? Enhance security?' says Robert McKeel,
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operations vp, GE Cisco Industrial Networks (Charlottesville, Va.). 'Then we see how particular
technologies may help users find the performance theyre seeking, and look at which technology makes
the most sense for that user.'
Even with simple networks, numerous variables must be considered. Layout type and concentration, wire
distances, component shielding, types of information transmitted, data packet sizes, system speed,
latency, I/O point concentrations, PLC methods, compatibility, hosts, master controllers, safety, personnel
training, maintenance, and expansion needs in three to five years are just a few. Environmental factors
including electronic and electromagnetic interference, area electrical classification (i.e. Class 1, Div. 2),
noise, vibration, hazardous substances, weather, available physical space and component crowding, and
installation locationsmust also be considered.
'The question is where is your existing network really feeling the pain? Because wherever you want to
add functions, then thats where you have to lay conduit and add cards to racks that are probably full
already,' says Perry Sink, regional sales and marketing manager, Synergetics (Downers Grove, Ill.). 'So
they wont be overwhelmed, many users prefer putting one toe in the water first.'
Instead of ripping out and replacing an entire network, for example, Mr. Sink says many users prefer to
add an industrial network, perhaps Profibus, Foundation fieldbus, or DeviceNet, to one or two motor
control centers with four nodes in an isolated plant area or lab. 'This gives the user a chance to convince
his manager that a fieldbus system wont be a disaster,' he adds. 'Many large networks start out this way.'
Renovation vs. replacement
Once all existing network aspects are identified, this list can be combined with functions the user wants
the new or revamped network to perform. This will give a good indication of what new components are
needed, and hopefully indicateafter costs are factored inwhether existing equipment should be
renovated or replaced. This can be the most gut-wrenching decision network builders face because:
Renovation may save money, but it can fail to deliver some needed functions, and may increase
incompatibility and integration problems between old and new components; and
Replacement can deliver more unified solutions, but its higher costs may outweigh overall
benefits achieved.
Determining when renovation is no longer more cost effective than replacement is made even more
difficult by unseen contributing factors. For example, renovation costs can quickly climb to replacement
levels if users are forced to disturb too many existing wires, cables, connectors, and other equipment.
Likewise, both replacement and renovation options are aided if there is enough space to leave old
hardwiring alone.
Cost, availability, support
Because of installation and maintenance issues, the cost of buying a control system amounts to only 20%
of the total cost of ownership over the 15-year lifecycle of a typical system, according to Dave Woll,
enterpise integration vp, ARC Advisory Group. The only users lucky enough not to have to choose
between renovation and replacement are those building new plants, now mostly in Asia and South
America, says Mr. McKeel.
Explains Mr. Sink, 'OEMs often know their material costs to the penny, for example, but many dont know
what percent of those costs go to network wiring materials and related labor. Once they do the math, they
often realize why they should implement a fieldbus system. Big users do these evaluations, and smaller
users need to do them too.'
For many users, however, an undeniable peace of mind comes with picking a well-supported network that
seamlessly meshes with an existing installed base. Network selection may tie users to one vendor or set
of vendors and limit access to some desired functions in the future. For example, two competing vendors
may target the same network space, but one has more available functions. Users may not feel the need
for these added functions now, but they should evaluate whether theyre likely to be needed in a few
years, and consider securing them in the present for use in the future.
Several system integrators report that many users simply dont have the time to learn about every fieldbus
protocol, and so theyre willing to sacrifice some potential flexibility they probably wont need in exchange
for a 'proprietary' solution support by one or a few vendors. Long-established solutions also tend to have
more readily available product and support. Also, going with one solution or protocol means less training,
which can be another significant cost.
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To secure appropriate network components and work intelligently with vendors, several integrators say
users can educate themselves and their employees, add checklists and benchmarks to specifications,
and use integrators that specialize in those vendors. Many vendors also have test drive programs of their
systems, and users should experience these when available. 'Vendors will generally accept
benchmarking requests and will try to meet specific requirements as part of their proposals,' adds AIGs
Mr. Chappel.
Ethernet, wireless emerging
All roads are beginning to lead to Ethernet, even of not everyone is walking them yet. Though other
networking methodsincluding physical media and fieldbus protocolsmay prosper and survive for
decadesjust as pneumatic, hardwire, and PLC controls persevere todaymuch of the organic growth in
control and networking will likely occur among Ethernet-based applications.
'Ethernet is becoming the de facto standard in our industry. Everyone seems to be using 100 base T
connections. My engineering staff is standardizing on it,' says Mr. Chappel. 'In the past six months,
everyone had also started talking about connecting through web pages for monitoring and non-critical
applications.'
However, while a traditional network may be able to display data via the Internet data, it likely has to pull
that data back into a database, and then serve it to a web page. A purer Ethernet solution may use an
embedded web server to deliver information directly, which is reportedly faster than going through a
database. Again, users must investigate these differences relative to their own applications and apply the
most appropriate solution.
Ethernet will likely replace many control system methodologies, but it wont replace the need for users
and integrators to perform thorough systems evaluations, ask intelligent questions, develop precise
specifications, and require that suppliers follow them. 'If you truly understand an application, that
comprehension will lead you to the right decisions, and help narrow your choices when building a
network,' says Synergetics Mr. Sink. 'Then you can take a specific list of requirements to vendors, cut
through the jargon, and focus on proven components.'

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