Migration is Key to Support & Transform Legacy Industrial Infrastructure (Local & Distributed) to IP-Based Networks

Transcription

1 Migration is Key to Support & Transform Legacy Industrial Infrastructure (Local & Distributed) to IP-Based Networks PCN Technology, Inc. (PCN) Via Esprillo San Diego, CA Key Words: IP-485, legacy, industrial, automation, control, distributed, intelligence, network, infrastructure, Serial, migration, IP, Ethernet, upgrade, cloud connectivity Abstract: Traditionally, installation and systems managers have focused Suppliers of industrial automation and distributed control infrastructure & products on reliability and predictability rather than network efficiency or convergence. This has resulted in an install base of industrial networks engineered, appropriately, to operate reliably in the specific application and environment for which they were designed, closed, and operating using a myriad of physical layer communications and language protocols. Product obsolescence, limitations in scalability of the infrastructure and potential loss of highly skilled (contracted or on site) support all have become high Pareto challenges to managers. In this paper, we introduce a new approach to modernization of industrial automation & distributed control networks. It is based on managed migration rather than a total rip and replace. Critical to the success of this strategy is the use of a technology and product solution called IP-485 which enables a phased changeover from legacy to modern, and thereby significantly reducing both the technical risks and project costs incurred in the process. We show specific examples of migration within industrial networks in conclusion to highlight both how broad and easy the transformation of legacy industrial networking infrastructure can be with IP-485. I. Introduction Industrial Automation Networks & Distributed Control Systems control and automate the operations of machines, devices, and sensors that manufacture products on factory floors; or perform processes within complex and distributed intelligent systems. In most cases they almost always operate in some type of harsh environment and are often up and running almost continuously during all three shifts in a day. Traditionally, therefore, systems managers have focused Suppliers of industrial infrastructure and products on reliability and predictability rather than on network efficiency or convergence. This has resulted in an install base of industrial automation and control networks that are engineered to operate reliably in their specific 1

2 application and environment, closed, and operating using a myriad of communication types and protocols (Proprietary & Open). Product obsolescence, limitations in scalability of the infrastructure, and potential loss of highly skilled (contracted or on site) support all have become high Pareto challenges to network and systems managers. Further, the continued move of services to the Cloud and a view that everything can be modeled and implemented as a Service convergence between industrial networks and the Corporate IT Infrastructure has become a key driver of modernization. The industrial networking market is going through a transformation as a result in the drive to modernize and connect the legacy communication infrastructure to the corporate network and deliver Cloud-based services to increase productivity and reduce operating costs. Modernization of legacy industrial networking faces several challenges. First, any approach based on a complete rip and replace of the cabling infrastructure is unlikely to have broad resonance across the industry due to the excessive capital costs, long down times and significant technical risks involved in the project. On the other hand, the performance and reliability challenges of using wireless technologies operating in harsh environments conflict with the need to maintain low and predictable network latencies and high uptime. Secondly, integration of the legacy infrastructure to the corporate network is an involved process that combines solving technical issues as well as streamlining policies and procedures. As a result, industrial network managers are often at a loss as to how best to design their modernization program, and how to manage the technology changeover. In this paper, we propose the application of a technology and related products called IP- 485 for the rapid and reliable modernization of industrial and distributed control network infrastructure. We demonstrate that the technology alleviates several key difficulties currently faced by network managers enabling them to think of modernization through migration, rather than only a rip and replace. In particular, IP-485 : - In Real Time Transforms Legacy Copper to operate as if it were a CAT 6 cable thus allowing new advanced IT operations and applications without impacting legacy functionality. - Addresses product obsolescence issues in legacy networks, and puts in place the initial infrastructure support required for the implementation of a technology changeover. - Enables the design of migration strategies that describe how networks can be gradually stepped through a phased modernization program. 2

3 - Enables seamless convergence of the industrial & distributed control network to the corporate IT in each migration phase, and the delivery of services to those upgraded portions of the network. Challenges in the Modernization of Industrial Networks To explain the solution we have utilized an example Industrial network within a local environment which typically can be described using a three level architecture (Figure 1). At the highest level within a local industrial facility, there usually is a connection or connections of the entire plant infrastructure to the corporate network. Using this connection, the corporate network has the ability to connect to a select number of servers that are programmed to collect certain plant data critical to the corporate Enterprise Resource Planning (ERP) system. Generally, information collected is restricted to inventory and material flow, and utilized using a variation of a Just in Time model to exercise supply chain. The corporate network, in cases where modernization is already underway, may also have the ability to manage production in limited ways. Figure 1: Typical Industrial Network The second level of the industrial automation architecture, and perhaps the most interesting for IP-485 is called Supervisory Control and Data Acquisition (SCADA). It consists of the brains of the actual industrial network and schedules and commands all of the machine control and sensor data acquisition tasks. In a sense, it runs the minute-by-minute operations of 3

4 an entire factory or overall distributed network installation. The command and communication protocols used by SCADA controllers to run the factory are many times closed and or proprietary. Newer SCADA controllers are equipped with RJ-45 ports and communicate via IP protocols with the server and the corporate network. The final level consists of Remote I/Os (RIOs) and Programmable Logic Controllers (PLCs). RIOs are used to facilitate the communication between SCADA controllers and PLCs, and the latter, in turn, actually execute the control programs that run machines and acquire sensor data at the edge. For this paper, we will assume RIOs and PLCs use Serial communication. Modernization of industrial networks require a changeover of SCADAs and PLCs from serial communication and related language protocols (proprietary or open) to IP protocols, which in turn facilitate the seamless integration of the corporate network all the way to PLCs and to sensors all the way at the edge. The primary challenge in the transformation is the rip of existing wiring infrastructure that connects the SCADA to the RIO and PLC, and its replacement with structured cabling as this necessitates a shutdown of entire factory lines or operational segment over a significant period of time. In addition, since IP communication is specified to Long Range Ethernet (LRE) distances of 100m (which is often much less than the specified bus length of the legacy serial system), there would have to be network design considerations to select Ethernet Extender products that can extend the range of communication beyond 100m and/or have switches at LRE distances to repeat the signals. And finally, there are cost issues to consider as well. Industrial structured cabling for IP communication is very expensive, and a project involving the deployment of cabling in an industrial environment is labor intensive and requires much planning. As a result, the transformation of industrial networks is burdened by high technical and project risks and high costs as well as the loss of revenue due to downtime. In this paper, we argue that the need to modernize industrial networks has moved to a point of criticality due to the confluence of three secondary factors. The first relates to product obsolescence. Many OEMs and product manufacturers in the industrial market are facing significant challenges from their component suppliers who have announced End of Life (EOL) on their older chipsets. This is manifesting itself in a wave of product obsolescence announcement from major industrial manufacturers which will begin to impact the industrial networking infrastructure in the coming years. Many of these manufacturers have offered only IP-enabled controllers and other Edge devices as alternatives to the older products facing EOL. This forces facilities and network managers to accelerate the transformation of their current infrastructure. Second is due to a push to make ubiquitous Human Machine Interface (HMI) panels that supervisors can use to monitor production flow, perform a process, control a device, 4

5 or respond to alarms. While the ultimate vision of this from a consumer perspective would be to have the HMI integrated as an App on a Smart Phone, which can be done, the approach that is prevalent is to place a number of HMI panels throughout the network capable of interacting with specific SCADA and PLC controllers and performing the necessary monitoring and alarm response functions. These panels are IP-enabled and need to be tightly integrated with the industrial network infrastructure, which is serving as an additional impetus for managers to consider modernization of their infrastructure. And the third is the integration of the industrial network to the corporate IT infrastructure for a variety of services to be deployed and utilized to better manage production and process flow (especially in a multi-facility manufacturing operation or distributed control network), to improve efficiency, safety, reduce overall costs, and deploy new applications. In this paper, we introduce a technology called IP-485 and describe how it can be used to transform functional legacy industrial network infrastructure using a phased migration approach. It achieves all of the goals for facilities, plant, control and network managers as if CAT 6 were deployed instantly; but with reduced technical and project risks, reduced costs, and minimal downtime all while maintaining the existing functionality already in place. IP-485 Technology At the heart of the phased migration strategy is a technology called IP-485 which enables the simultaneous transport of IP data and Serial data over the same wiring infrastructure (twisted or untwisted pair, current loop, specialized industrial cabling, proprietary cabling, etc.), even in the presence of significant conducted and radiated noise in the medium. The foundation of this technology lies in algorithms called Dynamic Adaptive Channeling which decide in real-time how to encode data payloads into communication frequency channels, so that Quality of Service (QoS) can be maintained at all times subject to channel constraints. The algorithm starts with a full spectral sweep and a determination of the Signal-to-Noise Ratio (SnR) properties across the entire channel. To make the problem computationally elegant, the algorithm divides the overall communication channel into Orthogonal Divisional Frequency Multiplexing (OFDM) sub-channels and conducts the SnR analysis at the baseband associated with each sub-channel (shown in Figure 2). This helps determine available sub-channels at a given Quality of Service (QoS), which in turn maximizes the utilization of usable channel capacity. 5

6 Figure 2: Dynamic Adaptive Channeling Adaptive Channeling is a real-time channel optimization policy and permits the deployment of robust communication networks in harsh environments. The algorithm is robust to white noise in the channels which degrade the communication bandwidth, and colored noise in the channels arising from factors such as EM interference from nearby operating equipment. In addition, it automatically discovers usable communication channels regardless of the type, gauge or topology of wiring used. As an example, IP-485 operates successfully on 18-gauge, twisted pair, multi-drop wiring, untwisted pair, simple daisy-chained wiring and other specialty cabling. Communication is robust to collisions arising from other applications currently using the channel, which are seen as interferences in channel analysis. This enables the technology to implement multiplexed channel access across applications at the physical level. In addition, if more than one OFDM sub-channel is available for communication, the technology enables the implementation of a Bus consisting of sub-channels that run concurrently, each of which may be multiplexed between applications. The second set of properties manifest in PCN s IP-485 relates to real-time network management at the application level. Concurrent with the adaptive channeling algorithm, we also implement a real-time communication engine that enables the delivery of serial data (that is multiplexed with IP data) using critical latency requirements already in place, encoded in jitter free, at copy-exact waveforms, regardless of wiring type, noise, interference of other considerations that affect signal integrity. Further, we also implement a network engine that enables network configuration and management in real-time. For example, in a Master-Slave configuration, the concept of a Floating Master may be implemented using the engine. Further, data payloads with high priority may be queued and delivered with very low latency across the network. Network data is not impacted and remains intact. IP-485 Networks Figure 3 shows a sample network established using IP-485 network products. It consists of a Server that is connected to the Corporate Network via an ISP line (T1, Fiber or 6

7 Satellite) using a standard CAT 5/6 connection. It is also connected to serial network(s) on its Low Frequency (LF) Bus(es). The PCN Single Channel Server (SCS) accepts a single serial network connection (shown in Figure 2), while the Multi-Channel version (MCS) permits the integration of multiple serial networks, each on a distinct wiring infrastructure. The Server then transports both IP data and Serial data on the same output channels, repurposed to be called the Broadband (BB) Bus. The SCS has a single BB Bus, while MCS would have many separate BB Buses as Serial network inputs on the LF Bus. In this architecture, the Shared Wire multichannel, multiplexed access bus is implemented on the repurposed BB Bus wiring. Each IP-485 Server is connected to one or more PCN Single Channel Clients (SCC) on the BB Bus. A SCS is capable of receiving multiple IP device inputs driving numerous SCCs for smaller networks to multiple addressable sub-networks; while a MCR has the capacity to drive many SCCs across many different wiring infrastructures for local area networks and distributed networks. Each SCC has a BB Bus port that is used to connect to its Server. On the output side, serial networks can be connected to its LF Bus allowing continuation of the serial network to its standard distances; and IP devices can be connected to the 3 RJ-45 ports available on each client. Networks designed with MCSs and SCCs have the ability to integrate up hundreds of IP Edge devices, and run many separate serial networks, each potentially having different protocols. In each case, the IP network co-exists with the Serial, or legacy protocol network without any impact on the performance of one network from the other. 7

8 Figure 3: IP-485 Network Architecture Migration Using IP-485 Networks Figure 4: Typical SCADA PLC Architecture Consider a typical industrial network segment between a SCADA and the RIOs and PLCs that it controls downstream using some dedicated cabling infrastructure. The SCADA controller communicates with all of the devices using one of a variety of physical level serial communications (RS-232, RS-422, and RS-485) and related communication or language protocols (e.g., Modbus, Can, Fieldbus, DH, Profibus, Etc.) The cases below discuss a local area RIO but also can be applied to Distributed I/O through network design and placement of IP-485 modules. We will consider five Use Cases to discuss the power of IP-485 in developing migration strategies that accommodate new requirements on the infrastructure without any wiring change-outs: 1. One or more of the PLCs utilized in the segment fails but cannot be easily replaced since it is beyond EOL or facing obsolescence, and the only option is to go to a newer IP-enabled version of the product. 2. There is a need to integrate an IP-enabled panel that can be used to monitor the status of one of more of the PLCs in the segment from a location other than the monitors attached to the SCADA controllers. 3. There is a mandate to change all PLCs in the segment to IP-enabled PLCs to increase the cyber security of the entire SCADA infrastructure. 8

9 4. There is a need to integrate the SCADA controller to the corporate network 5. There is pressure to integrate new IP-enabled devices such as cameras for plant safety and physical security. Product Obsolescence: Figure 5: Dealing with Product Obsolescence using IP-485 Consider a scenario where the PLC at the end of the segment connected to a RIO and the PLC before it have failed. The manufacturer has announced EOL and has recommended a newer version that is IP-enabled as a replacement. It is no longer supporting the older version, and limited amounts of refurbished units available through distributors are priced at a significant premium. In this case, but splitting the wiring at the head-end, connecting the output of the old SCADA controller to the LF Bus of a SCS, and the other end of the split wiring to the BB Bus of the SCS, we have immediately re-purposed the existing wiring to become capable of carrying both the serial data from the SCADA controller, and accommodate the transport of IP data. As a second step, we connect either the IP of the old SCADA controller (or, as shown in the figure, connecting a new IP SCADA controller in the event the old controller is not IP-enabled), at the head end to the RJ-45 port of the SCS. Following this, if we connect a SCC at the location where the failed PLCs have to be replaced with IP PLCs (as shown in Figure 5), we have enabled connectivity between the new PLCs and the SCADA without any need for structured cabling. This not only solves the immediate challenge faced by the facilities manager by addressing the replacement of the failed PLC that are past EOL, it also provides a path to the 9

10 migration of the infrastructure into a full IP-enabled network - gradually, in a phased manner, every PLC on the BB Bus can be switched to an IP PLC. IP Panel Integration: Figure 6: Integrating an IP Panel to the Network using IP-485 The second application considered is one where the integration of an IP panel is required for the facilities manager to monitor and control the production line directly from the panel using its HMI interface functions. In the example shown in Figure 6, the integration is at the end of the segment, and can be implemented by, once again, splitting the wiring at the head-end, connecting the output of the old SCADA controller to the LF Bus of a SCS, and the other end of the split wiring to the BB Bus of the SCS. As a second step, we connect the IP port of the old SCADA controller at the head end to the RJ-45 port of the SCS. Following this, we connect a SCC at the end of the segment and simply connect the IP panel to its RJ-45 port. This completely integrates the panel to the SCADA controller without any new wiring, and, as before, provides a path to the migration of the infrastructure into a full IP-enabled network. Integrating the SCADA Controller to the Corporate Network With IP-485, getting the network segment connected to the corporate network is also pretty straightforward. As shown in Figure 6, we begin by splitting the wiring at the head-end, connecting the output of the old SCADA controller to the LF Bus of a SCS, and the other end of the split wiring to the BB Bus of the SCS. As a second step, we locate an IT closet along the network segment that can establish a network connection to the corporate network. Then we 10

11 deploy a short CAT 5/6 cable run from the closet to a new IP SCADA and connect it to the BB Bus using a SCS. This completely integrates the older SCADA controller with the new IP SCADA controller, and in turn gets integrated into the corporate network. Figure 7: Integrating SCADA to the Network using IP-485 And finally, integration of other Edge devices can be achieved using the architecture shown in Figure 5 by replacing the IP panel with cameras, access control panels, and other IP devices. As before, this also provides a migration path for the legacy infrastructure. Scalable, Reliable, & Secure In any legacy system, whether local or distributed; IP-485 systems are scalable allowing the placement of devices where needed allowing the accommodation of data at any length ensuring the transport and access of IP data networks in areas traditionally not thought practical. IP-485 products should be functionally viewed as intelligent or smart wire as if CAT 6 were installed but with added features and benefits unattainable with simple wiring or cabling. Importantly, IP-485 products also allow unique reliability and security features. For added reliability, above and beyond Dynamic Adaptive Channeling algorithms operating in real time, IP-485 products also have unique fault detection and squelching functions that isolate any network or connected device fault, keeping it localized so that the fault does not bring down any aspect of the network. Finally, security is a huge issue within industrial networks and although IP-485 products transport the security measures from the connected devices for which it is transporting just as a CAT 6 cable would; IP-485 products also have additional security and encryption algorithms available to network managers adding additional levels of security and encryption translating to an even more secure network. With IP-485 network owners now have the ability 11

12 to utilize proprietary algorithms and encryptions on top of existing standardized algorithms allowing unique security features for applications. These can be deployed across the entire network or in specific parts. Conclusion In this paper, we have presented a technology called IP-485 and have described how it can be deployed to easily, rapidly, securely, reliably, and cost effectively transform existing legacy industrial network infrastructure into one that can support IP-enabled devices that are connected to the Cloud. The technology can be applied successfully in a variety of local and distributed network configurations. IP-485 operates using numerous types of physical layer communications and data protocols (open and proprietary) already operational within Legacy Industrial systems. It operates on twisted and untwisted wiring of many types in standard networking topologies along with critical daisy chain or multi-drop topologies. It allows the very easy placement of Ethernet within legacy industrial settings and hard to reach locations without impacting existing communication network or business operations within harsh installations and environments; either inside or outside. This allows managed migrations as needed in critical locations. The products have been developed specifically to allow migration and IP connectivity within Industrial, Building, Oil/Gas, Energy and Transportation operations that require real time reliability and security; but that also need to continue to modernize to open standard IP enabled networks to achieve new functionality, additional security, new applications, remote network management and other IT functionality such as virtualization and other forward looking functionality such as (SDN) Software Defined Networking and big data storage and analytics for the world s critical manufacturing, energy, transportation, and overall critical living infrastructure. IP-485 provides a secure and scalable migration path by transforming functional legacy copper to become simultaneously operational as if it were a CAT 6 cable at any length. Additionally, IP-485 products are strategically designed to plug and play into industrialized environments to self-configure and rapidly deploy IP enabled Ethernet anywhere into hotpluggable networks while also providing critical reliability and security functionality both within the local area, but all the way from the Cloud. By combining the IP-485 copper transformation with strategic product design ; IP- 485 allows a managed and cost effective way to rapidly upgrade critical legacy systems of yesterday to the advances in IT today without the traditional costs and risks. It provides an 12

13 economic path for network owners to be able to accelerate their network advances with less CapEx budget for installation and integration; while reducing integration risk due to elimination of shutdown and by keeping business and network operations in place while the migration takes place. IP-485 products interface seamlessly with Zigbee, Wi-Fi, 4G LTE, Fiber and other communication and network types. IP-485 products are being deployed today within Industrial Automation networks, Oil and Gas networks, Building Automation networks, and Transportation networks. IP-485 works with standard digital networking products by manufactures like Cisco, Juniper and others; while seamlessly operating with Industrial products from manufacturers like ABB, Rockwell, Siemens, Schneider Electric, GE, Honeywell and of course working on standard and proprietary cabling from companies like Belden, Panduit, Commscope and others. #### 13