Unlocking the potential of modern piping systems with seamless connectivity

Benedikt Spielmann , Product Manager Digital Connectivity at Swiss flow solutions provider GF Piping Systems, explains how a combination of smart devices and Industrial Ethernet can make production plants more cost-effective, efficient, simple, and future-proof.

Piping systems are essential to the safe and reliable transport of fluids and gases in sectors such as water treatment or the chemical process industry (CPI). In order to meet the demands of increasingly complex production processes, more and more plants rely on process automation which requires a wide array of connected field level devices like actuated valves and sensors. However, the implementation of these devices often leaves room for optimization, Benedikt Spielmann explains.

?

Over the past six years as an expert in the field, the product manager for digital connectivity has found that most process plants still operate completely analog systems on the field level. “The status quo is still very much focused on a traditional setup using a central PLC (Programmable Logic Controller) that is equipped with I/O cards and requires a point-to-point connection to every single device.” While this is not an issue in small plants, scaling this approach can result in wiring that is highly complex, takes up a lot of space, and quickly drives up costs. Another consideration is that analog technologies also lack the ability to extract additional data from devices, Spielmann adds. “Electrical signals that operate at 4-20mA, for example, are only capable of transmitting one value between a device and the PLC, effectively leaving out valuable diagnostics data that many modern devices can provide. In the context of growing digital trends such as Industry 4.0, predictive and preventive maintenance, and data-driven decision-making, leveraging the available data is becoming more important.”

Despite the widespread use of analog electrical signals to automate plants and skids, digital alternatives have existed for many years. Nevertheless, fieldbus technologies like PROFIBUS or Modbus RTU, which can extract more data from smart devices, have not been able to fully replace analog systems. “Most likely, this is due to their perceived complexity, as plant operators are simply not specialized in digital communication technologies. As a result, the question arises how to implement a solution that is easy to install and operate. We believe that the answer is Industrial Ethernet.”

?

Ethernet has the advantage of being a very widely adopted technology. There is a digital gap, however. While most plants are connected via Ethernet on the supervisory, planning, and management levels, this connectivity does not extend down to the field level. “In order to avoid the challenges of technologies such as fieldbus, it makes sense to take advantage of existing infrastructure”, Spielmann argues. Ethernet provides operators access to any type of data from field devices thanks to high data rates – even remotely, if necessary. And, instead of an unfamiliar and complex communications technology, Ethernet-enabled digital devices mirror consumer technology. In addition to the familiar ease of use, Industrial Ethernet cables and connectors are designed with safety in mind and can withstand harsh conditions such as varying temperatures, humidity, corrosive substances, dust, or vibrations.

?

But what does this mean in practice? For certain applications, it is essential to better understand the devices and processes. A typical example is water reuse: In an effort to save valuable resources, companies treat their wastewater so that it meets the same standards as “fresh” process water acquired from an external source. “This type of recycling is only possible with a data-driven approach, as seamlessly connected devices on the field level provide real-time data streams that can be used to continuously monitor, control and analyze,” Spielmann emphasizes. Water treatment or chemical processing plants can also use this data to plan and predict maintenance intervals, receive live insights into device diagnostics, or to increase performance with the help of accurate digital process values. Spielmann explains what this looks like for one of GF Piping Systems’ actuators: “Our updated Electric Actuator can be configured with an Industrial Ethernet accessories card. This allows operators to set and determine the actual position as a percentage value instead of just ‘open’ and ‘closed’, monitor cycle times or the motor current to receive insights into the condition of components like valve seals, display the device’s total cycles as well as the remaining cycles until the next service interval, and extract any type of diagnostic data for maintenance insights.” Furthermore, devices like the Electric Actuator come with an embedded web server which gives operators the option of accessing live data. In addition, the web server allows them to remotely program end positions and update the software, or to download manuals and logbooks without having to open the housing.

?

Generally speaking, setting up Industrial Ethernet follows the same principles as analog networks which require PLCs, cables, and devices. The main differences are that there is no need for expensive I/O cards, the necessary cabinet space and number of cables is reduced, and the overall system is simpler to install. In addition, Industrial Ethernet relies on digital connectivity protocols to ensure the best possible performance. “There are plenty of protocols to choose from”, Spielmann elaborates. “For the industries that we serve, we focus on PROFINET, EtherNet/IP, and Modbus TCP, which are already established technologies for factory automation.” On a basic level, they define how field device data can be accessed by a control unit (e.g. PLC) as well as the architecture of a network. This includes cyber security mechanisms, or redundancy concepts, for example. Ethernet protocols differ in their features and their PLC support, which means that operators can select whichever protocol is best suited to the specific application.

?

While Industrial Ethernet promises many benefits for modern industries, it is also important to discuss security concerns. Digital devices must be protected from external attacks, as well as unauthorized device and network access. GF Piping Systems’ connectivity expert emphasizes that security is a key consideration during the development of smart products. “Going back to the example of actuators, security is a collaborative effort. On the one hand, operators must ensure that access to the physical devices is limited while we provide security mechanisms which ensure that the actuated valve can be used in a secure network.” He also stresses that it is important in this context to select components that adhere to recognized guidelines. ?“At GF Piping Systems, we are certified by TüV according to IEC 62443-4-1 which has become a leading industrial cybersecurity standard for all types of plants, facilities, and systems across industries.” Crucially, this standard does not solely focus on the technology itself, but takes work processes, countermeasures, and employees into account. “Another important standard for us is IEC 62443-4-2, which addresses the security of a specific device. For example, the implementation of the web server in our Electric Actuator meets the Security Level SL-1, offering protection against unintentional or accidental misuse,” Spielmann adds.

?

Just as in other sectors, digital trends in the water treatment and chemical processing industries are here to stay, and it is likely that connectivity and Industrial Ethernet will experience dynamic changes. “For us, the goal is clear. At GF Piping Systems, we want to fully integrate the field level into a consistent network that uses data to simulate and optimize processes virtually before implementing them,” Spielmann explains. From a personal perspective, the connectivity expert is optimistic about the development of process automation, as well. “Terms like ‘Industry 4.0’ or ‘Digital Twin’ might still seem like buzzwords today, but I believe that they will soon become more tangible. Seamless connectivity is the basis to turn them into a reality, and we are motivated to continue developing impactful solutions.”