Technological Leap for Higher Availability Through Ethernet-APL
The Application
The process control system of a natural gas cavern storage facility, which had been in use for many years, needed to be upgraded to the latest technological standards. The client was a leading energy supplier. They wanted to take the opportunity to implement Ethernet-APL to achieve transparent communication between the control system and a multitude of sensors.
A cavern storage facility is an artificial cavity carved out of a solid salt dome. The salt serves as a gas-tight environment for the temporary storage of natural gas. Storage facilities of this type are an essential component to secure an uninterrupted gas supply.
The Goal
For an energy supplier, maximum availability of the entire facility for filling and withdrawing natural gas is paramount. Therefore, communication to the individual field junction boxes is designed with media redundancy.
The upgrade project implemented by Pepperl+Fuchs enhances this inherent plant security with improved protection against cyberattacks by equipping all enclosures and control cabinets with cylinder locks for increased access control. Several measures were also implemented to simplify workflows and engineering.
The Solution
The requirement was seamless communication across various signal types, such as 4-20 mA, HART, Profibus PA, and Profinet via Ethernet-APL. Furthermore, significantly improved maintenance and servicing were to be achieved to ensure plant availability even under critical operating conditions.
The integration of Ethernet-APL switches, and remote I/O in a single enclosure solution provided crucial prerequisites. The fully digital communication path not only enables seamless remote diagnostics but also the implementation of proactive maintenance concepts.
Technical Features
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Ring-redundant network infrastructure for high system availability
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Fiber optic communication with pluggable SFP modules for long-distance and outdoor signal transmission
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Immunity to electromagnetic interference through fiber optic technology
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Stainless steel enclosures with cylinder locks for infrastructure components
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Integrated heaters with thermostats for reliable operation in outdoor environments
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Individual power disconnection via MF-T type terminals, suitable for hazardous areas
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Integrated I/O modules in ready-to-connect enclosure solutions to ensure functional safety
The Benefits
A consistent standard for infrastructure components was developed, which will be used company-wide for all geographically distributed communication networks in the future. This ensures uniform handling during installation and maintenance, simplifying and accelerating work processes.
A standardized field distributor facilitates device replacement and simplifies engineering for minor system expansions.
Remote diagnostics with Ethernet to the field not only supports accelerated fault detection, but also ensures rapid response times, thus contributing significantly to maximum plant availability.
Results at a glance
- Maximum protection of the process plant against external attacks thanks to stainless steel enclosures with cylinder locks and locking systems
- Optimized cybersecurity and integration of functional safety
- Simplified engineering and maintenance through end-to-end digitalization with Ethernet-based communication
- Comprehensive remote diagnostics for increased plant availability through proactive and accelerated maintenance
- New company-wide standard for all infrastructure components for accelerated engineering and maintenance tasks
Based on our partner Pepperl+Fuchs
