In the process industry, plant operators face major challenges: efficient engineering, precise plant design, fast commissioning and the manufacturing of products with maximum efficiency and quality. Digitalization holds the promise of unlocking new solutions by using valuable process data for optimization. However, while many digitalization projects focus on connecting information sources to company-wide systems, a vast data treasure remains largely untapped: extended diagnostic information and additional process values from field devices. These data could enable predictive maintenance and prevent unplanned downtime, but traditional technologies like HART, PROFIBUS, or the 4–20 mA standard are reaching their limits—low speed, limited bandwidth, and the complexity of protocol conversions hinder progress. Until recently, Ethernet was largely restricted to office use in the chemical industry. ut with the introduction of a new physical layer—Ethernet Advanced Physical Layer (APL)—this technology has emerged as a major driver of industrial digitalization.
The key to unlocking hidden data
Until recently, the use of Ethernet in many process industries was severely limited due to safety concerns. Now, the latest addition to the Ethernet family enables full Ethernet and TCP/IP connectivity even in hazardous environments such as chemical plants, the oil and gas industry, and hydrogen production facilities. It also allows devices in the process industry to communicate at high speeds over distances of up to 1,000 meters. Power and communication signals are routed via a single two-core cable. APL for Industrial Ethernet protocols such as PROFINET or Ethernet-IP marks a paradigm shift, as it overcomes previous limitations and closes the gap in the automation pyramid to the field level as a key technology.
Successful load tests prove market readiness of Ethernet-APL
To prove the performance of Ethernet-APL, Endress+Hauser conducted load tests in early 2023 that simulated realistic setups for the technology. The results of these tests clearly showed that Ethernet-APL meets the high expectations of the process industry. Nearly 240 Endress+Hauser measuring devices and components were tested for the interoperability and reliability of Ethernet-APL. The test results were conclusive: Ethernet-APL met all key requirements, including netload, scalability, fault tolerance and redundancy switch-over times, and even exceeded them in some areas.
High expectations from the industry
Ethernet-APL fulfills a long-standing wish among users: to gain seamless access from the enterprise level down to individual field devices, enabling data retrieval and aggregation, as well as resolving instrumentation and control issues directly from the control room. Thanks to the increased speed and reliability of the network, production processes can be made more flexible, and automated testing procedures can be carried out more efficiently. This leads to improved plant performance, reduced downtime, and lower maintenance costs. Plants also benefit from end-to-end connectivity, which simplifies access to components and enables rapid delivery of high-resolution process data. These data support condition-based maintenance and enable deeper diagnostics of plant conditions, which increases availability and makes maintenance intervals easier to manage. Additionally, within the Profinet environment, the use of Profile 4.0 allows for smooth device replacement in the plant.
Benefits in engineering
For engineering, i.e. the planning and configuration of the plant, Ethernet-APL offers a significant simplification. Automation and reduced component selection reduce the planning effort compared to traditional fieldbus topologies. In addition, direct wiring between field components and the switches enables faster and more efficient commissioning. These benefits help bring plants online more quickly, reducing both capital expenditures (CAPEX) and operational costs (OPEX).
Benefits for plant personnel
Personnel responsible for ongoing plant operations benefit especially from the increased speed of device communication via Ethernet-APL. With a data transmission rate of 10 Mbit/s, working with data-intensive applications such as parameter backups or continuous data evaluations becomes noticeably easier. The end-to-end network connectivity up to the highest levels of automation also simplifies access to plant components and enables faster response to operational demands. Overall, work for operations staff becomes more efficient and less error-prone, which positively impacts plant availability.
Deployment Begins: First Use Cases
Endress+Hauser is actively advancing digitalization in the process industry by aligning its measurement technology solutions with the innovative Ethernet-APL technology. Endress+Hauser supports a wide range of measurement parameters with Profinet-APL and also offers digitization services for Ethernet-APL. For flow measurement, the proven Promag and Promass flowmeters—equipped with Proline 300/500 transmitter electronics—are now available with the new Ethernet-APL technology as Profinet-APL variants. The Prowirl 200 vortex flowmeter is also equipped with Profinet-APL, which enables seamless integration into modern networks. In the area of level measurement, Endress+Hauser relies on the latest 80 GHz radar sensors from the Micropilot series, which also support Ethernet-APL. The Cerabar and Deltabar high-end transmitters are used for pressure measurement, while the innovative iTEMP TMT86 head transmitter is offered for temperature measurement. These devices offer high precision and reliability and are optimally designed for integration into Profinet APL networks.
A particular highlight is the continuous diagnosis, verification and monitoring by Heartbeat Technology, which is compatible with Profinet-APL and enables constant monitoring of the process conditions. In future, Profinet will also be integrated into the cloud-based IIoT ecosystem Netilion via Ethernet-APL, further expanding the possibilities for digitalization and networking.
Closing gaps and tackling challenges
The availability of Ethernet-APL hardware and software is already secured, and the expectations of those responsible for engineering, procurement, and operations are clear: they no longer want patchwork solutions made up of fragmented systems. In order to meet this demand, it is crucial that providers quickly and comprehensively adapt a significant proportion of their product portfolio to the new technology. These developments should encourage customers to favor Ethernet-APL when planning new installations.
While the technology offers enormous advantages, it also introduces new risks. In particular, web servers connected via Ethernet-APL present a larger attack surface for cyberattacks compared to analog devices. This represents a major challenge for the entire industry. Profibus International, the PROFIBUS user organization, is already working on cross-manufacturer standards for implementing cybersecurity solutions. However, these standards must go well beyond the requirements of any individual company and provide a comprehensive, industry-wide solution. It is critical that all stakeholders—from manufacturers to end users—collaborate to establish robust security standards that meet the demands of a modern, connected industrial landscape. Only then can Ethernet-APL reach its full potential and safely guide the process industries into a digital future.
