America’s Business Benefit Association

ABB's Ethernet-APL Technology Review

Brief Introduction and Overview of the Technology

ABB's Ethernet-APL (Advanced Physical Layer) is a specialized Ethernet physical layer designed for process industries. It offers high-speed data communication through a single cable with built-in safety features for hazardous areas [2][3]. Ethernet-APL revolutionizes communication in process automation, enabling faster, seamless data exchange between field devices while maintaining intrinsic safety. This powerful technology bridges the gap between standard IT communication and industrial Ethernet, setting a new standard for reliability and efficiency in demanding environments.

Overview

The development of Ethernet-APL began around 2015 with a consortium of leading suppliers in process automation, including ABB, Emerson, Endress+Hauser, and others [5]. The consortium recognized the need for a robust and reliable communication solution that could meet the specific demands of process industries. This led to a collaborative effort to define the key features and functionalities of Ethernet-APL.

Key Milestones

• 2017: ABB initiated the development of prototypes to demonstrate the suitability of OPC UA for transferring device data securely with sufficient performance and a low memory footprint [4]. This marked a significant step toward establishing OPC UA as a central component of Ethernet-APL communication.
• 2018: The consortium established that any solution must be fully compatible with the IEEE 802.3 Ethernet standard and satisfy specific criteria such as two-wire cable, long cable runs, power and communication on the same cable, and support for all explosion protection techniques [5]. This ensured interoperability and safety within process automation environments.
• 2021: ABB unveiled the first Ethernet-APL products at the ACHEMA Pulse virtual trade show, marking the culmination of a decade-long journey to extend Ethernet to field-level communication in process automation plants [4][5]. This launch marked a significant milestone in the adoption of Ethernet-APL as a viable solution for industrial communication.

Regulatory Compliance and Licenses

Ethernet-APL aligns with the IEEE 802.3 standard and adheres to specific criteria for process industries, guaranteeing compatibility and safety. It does not require additional licenses or certifications beyond standard Ethernet protocols [5]. This simplifies implementation and minimizes regulatory hurdles for users.

Ethernet-APL Applications and Benefits

Ethernet-APL is primarily designed for process automation and supports a wide range of field devices, enabling seamless integration with control systems. Its key applications and benefits are outlined below:

Main Applications

• Process Automation: Ethernet-APL is a perfect fit for process industries, enabling high-speed data communication and integrating with modern protocols like OPC UA for secure and efficient data transfer [2][4]. It enhances data integrity and operational efficiency across process automation systems.
• Field Devices: It supports a diverse array of field devices, including sensors, instruments, and transmitters, allowing for seamless communication and integration with control systems [3]. This expands the scope of devices that can leverage the advantages of Ethernet-APL.

Additional Benefits

• Reduced Complexity: Ethernet-APL eliminates the need for gateways or other protocol conversions, simplifying communication and lowering the cost of ownership compared to conventional fieldbus systems [4]. It streamlines system design and reduces maintenance overhead.
• Improved Usability: The technology is simple, practical, and easy to use, making it universally applicable in process automation plants [4][5]. This ensures ease of implementation and minimizes training requirements.

Integration with OPC UA

OPC UA plays a crucial role in Ethernet-APL's capabilities, providing a robust framework for secure and efficient data communication.

Overview of OPC UA Integration

• OPC UA Deployment: Ethernet-APL allows OPC UA to be deployed directly in field devices, facilitating easier integration with IT and OT applications [4][5]. This eliminates the need for separate gateways and simplifies communication across different system levels.
• Performance and Security: OPC UA provides data with semantic information, eliminating the need for fieldbus-type barriers and ensuring secure data transfer with sufficient performance and low memory footprint [4]. This guarantees data integrity and security while maintaining high communication speeds.

Customer Adoption and Implementation

Major industry players have embraced Ethernet-APL, demonstrating its viability and potential for transforming process automation. BASF's successful testbed project is a prime example of this adoption.

Customer Testbeds

In March 2023, BASF completed a successful testbed project, connecting over 200 devices, 10 field switches, and multiple control systems to validate Ethernet-APL's capabilities. ABB's Ability System 800xA was utilized in these tests, demonstrating the robustness and reliability of the technology [2][3]. This real-world implementation showcased Ethernet-APL's ability to handle complex communication scenarios and integrate seamlessly with existing control systems.

Future Plans

Following the successful testbed, BASF plans to equip new plants in Europe with Ethernet-APL technology, further solidifying its position as a leading technology in process automation [2][3]. ABB continues to spearhead the standardization of OPC UA-based devices, ensuring seamless integration and interoperability across the industry. This commitment to standardization will drive widespread adoption and foster a thriving ecosystem for Ethernet-APL.

Pros and Cons of Ethernet-APL

Like any technology, Ethernet-APL has its advantages and disadvantages. Understanding these aspects can help organizations make informed decisions about its implementation.

Pros

• High-Speed Communication: Ethernet-APL offers high-speed data communication, enabling faster and more efficient process automation. This reduces delays and enhances the responsiveness of control systems.
• Intrinsic Safety: The technology includes built-in safety features for hazardous areas, ensuring safe operation. This ensures compliance with safety regulations and mitigates risks in challenging environments.
• Robustness and Reliability: Ethernet-APL is highly robust and reliable, suitable for extremely reliable operation in process industries. This minimizes downtime and maximizes operational efficiency.

Cons

• Complexity in Implementation: While the technology itself is simple, its implementation might require significant investment in infrastructure and training. This necessitates careful planning and resources to ensure smooth deployment.
• Interoperability Challenges: Ensuring full interoperability in a multi-vendor Ethernet-APL network can be complex, requiring careful planning and testing [2][4]. This involves managing compatibility issues across different manufacturers and ensuring seamless communication across the entire network.

Conclusion

Ethernet-APL is a revolutionary solution for process automation, offering high-speed communication, intrinsic safety, and robustness. Its integration with modern protocols like OPC UA facilitates secure and efficient data transfer, making it a powerful tool for enhancing operational efficiency and safety in demanding environments. The technology's adoption by industry leaders like BASF underlines its viability and potential to transform the future of process automation [2][4]. As Ethernet-APL continues to evolve, it is poised to play a pivotal role in shaping the future of industrial communication.

Frequently Asked Questions about Ethernet-APL

Here are answers to some common questions about Ethernet-APL:

Answers to Common Questions

• What is Ethernet-APL? Ethernet-APL is a specialized Ethernet physical layer designed for process industries. It offers high-speed data communication through a single cable with built-in safety features for hazardous areas [2][3]. It is a robust and reliable solution for communication in demanding environments, offering significant advantages over traditional fieldbus systems.
• How does it integrate with OPC UA? Ethernet-APL allows OPC UA to be deployed directly in field devices, facilitating easier integration with IT and OT applications [4][5]. This seamless integration enables secure and efficient data exchange across different system levels, enhancing operational efficiency and data integrity.
• What are the benefits of using Ethernet-APL? Ethernet-APL offers a multitude of benefits, including reduced complexity, lower cost of ownership, and improved usability [4][5]. It eliminates the need for gateways or other protocol conversions, simplifies system design, and minimizes training requirements. These advantages make Ethernet-APL an attractive option for organizations seeking to improve their process automation capabilities.

References

• [1] https://global.abb.com/group/en
• [2] https://www.automationworld.com/communication/article/55014984/basf-completes-successful-ethernet-apl-tests-with-abb-dcs
• [3] https://www.chemicalprocessing.com/industrynews/news/33037699/abb-to-deliver-advanced-control-system-for-basfs-ethernet-apl-project-in-europe
• [4] https://library.e.abb.com/public/19baeb58fb7848beb655b847f11a9be6/60-67%20m0096_EN_72dpi.pdf
• [5] https://new.abb.com/news/detail/80779/abb-brings-ethernet-apl-with-opc-ua-to-the-field