Industrial Ethernet Book Issue 48 / 35

Profinet and Profibus - equal or sequel for Process Automation?

Profinet and Profibus - equal or sequel for Process Automation?
Profibus has more than 24m installed devices making it the most successful fieldbus in history. Its coverage domain crosses factory, discrete and
process automation. Profinet has many features in common with Profibus, including shared profiles, engineering and support plus absolute
compatibility with enterprise wide IT systems. Profinet can integrate Profibus networks and most other existing plant networks too. PI, the
organisation responsible for both Profibus and Profinet, is the largest of its type in the world with 25 regional offices, over 1400 member companies,
and a global network of certified support, certification and training operations.
Profibus has possibly more installed nodes than all those of its competitors added together. While PLC-based factory automation applications provide the bulk of
usage, the parent organisation, PNO claims some 4m installed nodes in Process Automation. The total value of the Profibus market is believed to be $50bn, and
all indications are that historic growth will continue. PI expects Profibus to pass 30m installed nodes before 2010 and for widespread use to continue well after
that.
Part of the Profibus value proposition relates to costings across the life cycle of a plant, from design, through maintenance phase, to major updates. It does this
in many ways: at the engineering stage it simplifies plant design, eliminates hard wiring and requires less hardware, leading to faster commissioning and
lowered costs. It supports better diagnostics, so commissioning is much faster. Profibus also assists productivity through the delivery of timely data to operations
and management staff; asset management strategies allow plants and equipment to be better managed and maintained.
A huge number of vendor companies have developed Profibus-capable devices for discrete and process automation, so system integrators and end-users have
real choice. Not only does this assist security and flexibility of supply, it also engenders healthy competition amongst vendors in a manner favourable to end
users.
The success of Profibus is underpinned by the global PI technical and administrative network. The applications coverage has been continuously extended to
include new and relevant functionality such as integrated Functional Safety and advanced Motion Control. Users have made substantial investments in training,
tools, inventories and plant. In short, the value proposition of Profibus has become correspondingly high.

Reasons for choosing Profibus

• Wide vendor and product choice.

• Openness and interoperability, allowing changes/updates at low cost
• Protocol optimised for factory and process control using standardised interfaces.
• Easy and consistent integration of functional safety and motion control for factory and process automation.
• Flexible media redundancy.
• Stringently managed technology development, including test and certification processes.
• Supported by PI, the world's largest fieldbus organisation.
• Easy migration to Profinet.
Case study: chemical industry
To meet the increasing demand for mica based pigments, Merck KGaA of Darmstadt, Germany, recently commissioned a ?60 million pigment production facility
at its Gernsheim plant. Nearly 2500 field devices were planned for the new plant.
Merck's engineers had not previously used fieldbus but they looked at available solutions and chose Profibus, due to the large number of devices available as
well as its high rate of acceptance. The need was for a solution that would handle both process and discrete applications without having to use multiple
networks. The company claims that no other fieldbus came close to matching Profibus' adaptability in both environments.
Merck's engineers performed a cost analysis, comparing the use of Profibus to hard wired I/O in terms of device, installation and engineering. While the overall
purchase costs of devices and Plant Automation System (PAS) hardware were slightly higher (due to the additional network interface), the analysis concluded
that substantial cost savings would be realised. The company estimated that it made a 19 percent saving on installation due to the reduced wiring necessary for
networked field devices, and as much as 36% on engineering.

Profibus enabled the use of 2-wire networks throughout most of the plant, augmented by fibre optic cabling for noise immunity and ring redundancy.
Prefabricated cables and T connectors helped reduce wiring errors as well as speeding up installation. The substantial savings in engineering and shorter
planning time resulted from greatly simplified CAD drawings due to the reduced wiring requirements.
Major cost savings also resulted from the decision to employ a decentralized Profibus architecture of around 60 sub systems, each comprising a standardised
electrical mini cabinet containing Profibus DP and PA links, local I/O blocks and power supplies. Devices such as drives, field instruments and other I/O devices
were connected to redundant PCS 7 controllers via the network. By designing these subsystems around a standardised Profibus architecture, engineers were
able to 'copy and paste' much of the plant design, simplifying the engineering and greatly reducing costs.
Using centrally located diagnostic and configuration tools, plant engineers can now configure a replacement field device or quickly locate wiring faults from
either of two redundant control rooms. The standardised sub systems support identical wiring in all parts of the plant, meaning shorter downtime during repairs.
Finally, when field devices need to be repaired or replaced, most can be 'hot swapped' without having to shut down the process.
The role of Profinet as a network solution
If Profibus is successful in automating factories and process plants, what convincing business advantages does Profinet offer? The answer is that it draws on
the experience of Profibus while opening the way forward to increasingly flexible automation strategies. Profinet intrinsically possesses enterprise-wide
connectivity for operational benefits and business advantages over the life cycle of a plant. It uses standard COTS Ethernet, but its move into industrial
environments has required care because of the special needs of automation. Profinet extends basic Ethernet with features that meet the needs of industrial real
time operations and the ruggedness expected by industry.
Technically, Ethernet's larger address space means more devices can be included in plant networks, with almost unlimited scalability. More bandwidth is
available too, for data intensive functions such as machine vision working alongside measurement and control. There's also more capacity for advanced
applications like Motion Control.
Ethernet is easily cabled and installed. Many diagnostic tools are available to support Profinet engineering, network management and maintenance and Internet
technologies can be deployed easily. Thus, production enterprises become globally accessible using standard web browsers. For managers this means better
managed facilities that can be fully integrated into the enterprise, enabling faster responses, better productivity and higher profitability. Profinet is modular and
scalable, so a Profinet system can be updated at any time. Modularity makes the adoption of Profinet systems more manageable and future proofed. A unique
'proxy' solution allows Profibus networks - including Profibus PA to be integrated with Profinet. The 'proxy' solution accommodates other fieldbuses too, for
example Foundation Fieldbus, DeviceNet, HART, Interbus and AS-i. In short, existing systems, skills and equipment are protected in any migration to Profinet.
Reasons for choosing Profinet

• All the same reasons for choosing Profibus, plus...

• Seamless enterprise wide integration, global accessibility.
• Unlimited node count, powerful capabilities, greater scalability.
• TCP/IP, internet and web compatibility, with real time determinism.
• Ethernet cabling eases installation, and familiar IT and Internet tools help during operation, maintenance and diagnostics.
• Wireless and functional safety easily added.
• Protects investments in plant and people by easily integrating all popular automation networks.
 • Strategic links with Profibus include common infrastructure, common engineering platforms, common quality assurance and common application profiles.
• Modular, flexible, comprehensive - use only what you need now.
• Easily extended and expanded as enterprise needs change.

eL-Tec Elektrotechnologie, located in Hattem in the Netherlands, is building an alarm system for a luxury sailing yacht, the 52-metre, single masted Boreas. The
company has a lot of experience in control and monitoring systems for ships but up to now has used separate control and service systems. For this ship, a more
powerful and extensive system was needed, so the engineering team explored new possibilities. The answer lay with S MAX, a Phoenix Contact PLC with an
integrated touch screen service panel (HMI) and a Profinet interface.

Four S MAX controllers are being used in the Boreas. Using Profinet these exchange data transparently with other equipment such as the motor management
and fire alarm systems. Profinet is certified for shipping and it handles the data transported between the PLC and the I/O modules and the normal Ethernet data
simultaneously in real time. The system has the required reaction speed, and it supports very fast visualisation. With the HMI integrated into the S MAX, costs
and programming hours are much reduced. The monitoring system controls and communicates with all vital functions of the ship - the motor, the valves in the
bilge pump, fuel and ballast tanks, fresh water tanks, the heating and cooling installations, fire alarms, battery system, the navigation lights and the deck lights.

Integrated touch screen service panel (HMI) and a Profinet interface. Four S MAX controllers using Profinet provide data exchange transparently with
other equipment such as the motor management and fire alarm systems
The simplest, and the most complicated, systems are handled with Profinet IO, from the dimming of the lights in the accommodation area to the hydraulic
system for reefing and hoisting the sails. Everything is done with a strong emphasis on energy saving. An important reason for choosing Profinet was the
savings realised in cabling. The whole system communicates via one Profinet fibre network, which delivers a big commercial advantage together with
considerable weight savings - important in ship design.
The ship is divided into six segments, each with its own managed Profinet switch which connects to the I/O devices around the ship. A separate glass fibre cable
has been installed which will only be used for this system, and the whole network is tightly secured against outside interference. The yacht will sail around the
world, so eLTec has proposed that a fully redundant system be installed. The primary system would then have a back up, which Profinet supports easily and
without too many extra costs. If the customer agrees, eL-Tec will also implement the software needed to let its support engineers in Hassen help the crew
remotely solve any problems that arise via the internet.

Common infrastructure, common applications

The synergy between Profinet and Profibus is based on an high degree of engineering commonality. Both offer genuine realtime capability, plus redundancy for
high integrity operations. Both feature IO solutions optimised for factory and process control. Engineering is replicated as much as possible to enable existing
Profibus skills and tools to be reused with Profinet. For example, the GSD files used for Profinet configuration are similar, and handled in the same way, as with
Profibus.
PI has based many of Profinet's capabilities on its 20-year experience of Profibus. Common application and device profiles deliver the same functionality and a
similar look and feel for both technologies in most application domains. The goal has been to embrace all applications areas presently served by Profibus.
Both Profibus and Profinet support process industry needs by ensuring factory and process solutions can be intermingled easily. This recognises that most
process plants today are hybrid - that is, they have discrete manufacturing functions working alongside field based instrumentation and control. The Profibus PA
protocol is exactly the same as the Profibus DP protocol used in factory automation, so engineering, tools and functionality are identical. Only the physical
interface is different, because of the need for power on the bus and Intrinsically Safe operations when used in hazardous areas.
For Profinet, process automation integration is made simple by means of 'proxies', which allow existing fieldbus based networks to be accommodated easily
inside Profinet architectures. Legacy investments in skills and equipment are fully protected when migrating plants to a Profinet based future since Profibus PA
can be used unchanged within Profinet applications.
Profibus and Profinet in joint action
ArcelorMittal, the largest steel corporation in the world, recently looked for a safe and reliable automation solution for transporting steel coils at their flat carbon
steel products plant in Ghent, Belgium. Coils, which can weigh 30 tons, first need to be lifted safely and securely from incoming rail wagons and then be placed
on 'saddles' in the stockyard (a temporary storage area). Later, they are picked up and delivered 'just in time' to the right production line.
The coils have razor-sharp edges and can often be at high temperatures, so there are critical personnel and equipment safety issues to contend with.
They are carried by overhead gantry cranes which use 'tongs' to pick a coil. Cranes weigh up to 180 tons and can reach speeds up to 1.6 m/s so, if a safety
hazard occurs, a crane must stop immediately. The economic consequences of late or wrong delivery of a coil are also high, as is coil damage. ArcelorMittal's
requirement was to transform an existing, 1970's, manually operated crane into fully automated operation. As well as the safety improvements sought, a Return
on Investment (ROI) of less than 2 years was specified along with a robust, reliable and open solution.
One of the first things the crane has to do is locate the exact position of a coil. Coil locations are stored in the company's MES system but minor variations in the
actual location of a coil are common. The position of train wagons is also uncertain, so the automated solution has to cope with many variables. This meant
building a new system from scratch.
The main processing power of the chosen solution resides in an HMI system linked to the company's LAN, and a PLC capable of performing a combination of
regular control tasks as well as failsafe functionality. Regular control tasks and safety tasks are handled across Profibus and Profinet together, using both copper
and wireless. The MES database prioritises all coil movements, transmitting data wirelessly to the crane via the Profinet network.

The 'brain' of the chosen solution is an HMI system linked to the company's LAN, and a PLC capable of performing a combination of regular control
tasks as well as failsafe functionality. Regular control tasks and safety tasks are handled across Profibus and Profinet together, using both copper
and wireless. The MES database prioritises all coil movements, transmitting data wirelessly to the crane via the Profinet network
To ensure safe operation, the crane has a laser scanner to survey its environment. Data from this scanner is used to create a 3D image of the surroundings,
which is stored in an industrial PC on the crane and used to determine if there are any obstacles within operating range. It's also used to pinpoint the exact
location of a coil, and it further allows the shape and condition of the coil to be monitored. This can be important if, for example, a coil's seal is broken and a flap
is hanging down that could damage other coils or cause mechanical problems elsewhere. The pick up 'tongs' of each crane are also fitted with sensors to
monitor activity, with a local PLC sending data to the failsafe PLC on the crane in case of problems.
To prevent unauthorised access to the stockyard, fences surround the entire area. There are 14 entrances, each fitted with safety interlocks and other sensors
linked to a local safety PLC through Profinet. Whenever a door needs to be opened during crane activity, this safety PLC transmits a signal to the crane's
failsafe PLC, stopping all crane activity immediately. The result at ArcelorMittal is a crane that can perform its task without human intervention thus reducing
costs and improving safety for both man and machinery. ArcelorMittal reports that not only was its ROI target met but that the installation was also brought in at
minimum cost. Wireless systems can also be useful when slip rings are involved because they can eliminate maintenance intensive mechanical components,
significantly improving reliability and delivering big savings.
For the future
Profibus and its crucial role in automation will continue for many years. Profinet and Profibus play well together, with many 'added values' coming from their
synergies. Technical overlaps and complementary technologies extend the value proposition. Both Profibus and Profinet support real time performance. Profinet
is fully Ethernet compatible. Further, Profinet offers unprecedented performance opportunities in Motion Control. Like PI's Functional Safety technology, the
Motion Control solution is common to both Profinet and Profibus. Profinet opens the door to new automation opportunities by leveraging the reach and scale of
the Web to make managers better informed and plants easier to manage. Profinet is providing a single point of convergence for enterprise systems and the end
point devices that drive modern automation. Profinet can support plant wide Ethernet networks as they are increasingly used for multiple purposes. Yet Profinet
never obsoletes existing systems or equipment.
The modularity of Profinet means not everything has to be used at once, so there is strong evolutionary energy in a Profinet solution. Additional devices and
functionality can be added easily to meet the advancing needs of plants and enterprises. Migratory options mean that Profibus devices can be used today with
the assurance that they will fit in with a Profinet system later. Other networks can just as easily be integrated too.
With its larger address space, greater bandwidth, enterprise connectivity, and peer to peer integration capability Profinet is on the way to become the leading
Industrial Ethernet Standard in automation. However, the conservative nature of manufacturing industry, particularly for process automation, means that Profibus
has a secure future. Remember, Ethernet itself is now more than 30 years old.
The success of Profibus is the base on which Profinet is now building its own success. Market momentum and the credibility provided by Profibus helps this
process. The innovative Profinet solution protects legacy investments and offers an easy migration path. Profinet is a great partner for Profibus, a factor that will
support continued growth for Profibus systems as Profinet's own popularity grows.
The article was written by consultants to PNO

Source: Industrial Ethernet Book Issue 48 / 35

© 2010-2020 Published by IEB Media GbR · Last Update: 12.03.2020 · 32 User online · Privacy Policy · Contact Us