1. Assessing and Designing Physical Networks that Enable the Connected Enterprise
Jason Ostrander
IA CAM North Central

2. Agenda
Connected Enterprise: Is your plant ready?
Assessing the Plant Network
Designing the Physical Network

3. Performance and Security Risks Due to Poor Planning
“A significant portion of network downtime, approx. 80%, is attributed to Physical Layer Connections.”
Sage Research
“40% list Security concerns as a barrier to enabling Internet connectivity to machines”
Industry Week Magazine Rockwell Automation Survey
Network Distribution Installation Pitfalls
Use this slide to briefly show the problems with improper installation practices.
Mention that without guidance and best practice instruction, a functionally well designed network can fall apart at the physical level and is more vulnerable to security risks.
Why is this important?
“A significant portion of network downtime, approx. 80%, is attributed to Physical Layer Connections.”
Why is physical infrastructure important to security?
Proper deployment and physical security can help (as part of DiD) to overcome concerns about security on the plantfloor and improve adoption of E/IP enabling technology to better meet business objectives.
Proper planning and Execution is essential!

4. Is Your Plant Infrastructure Ready?
Operations =
Day 2 (OPEX) maintenance plus other operational investment / CAPEX expenses like:
Resources (People to run the Data Center)
Mechanicals
Cell Phones, Pagers, etc…
Maintenance
Is Your Plant Infrastructure Ready?
Do you utilize CPwE best practices?
Do you have a structured physical infrastructure?
Are you future ready?
More nodes
More bandwidth
Mobile, remote access
If we look at typical spends on the network…
Software 60%; Networking 23%, Operations 10%; and Cabling Infrastructure 7%---look also at expectation for lifespan and turnover.
IT budgets spend most heavily on software and hardware, with a very small percentage of the budget going to cabling. However, up to 80 percent of network problems, which manifest themselves as other problems in the application, can be traced back to cabling. The tendency to correct issues is to go after a simplest approach possible…This can cause waste in capital budgets as unneeded device replacement occurs.
The other thing to notice here is the turnover on equipment vs. the physical layer cabling infrastructure…a company may upgrade networking equipment 4-5 times over the life of the cabling infrastructure, it pays to be forward looking when planning the cabling used.

5. Infrastructure Investment Compared to Longevity
Operations =
Day 2 (OPEX) maintenance plus other operational investment / CAPEX expenses like:
Resources (People to run the Data Center)
Mechanicals
Cell Phones, Pagers, etc…
Maintenance
Infrastructure Investment Compared to Longevity
Software
60% of budget
2 to 5 years
Networking
23% of budget
5 years
Operations
10% of budget
Cabling
7% of budget
20+ years (or forever!)
If we look at typical spends on the network…
Software 60%; Networking 23%, Operations 10%; and Cabling Infrastructure 7%---look also at expectation for lifespan and turnover.
IT budgets spend most heavily on software and hardware, with a very small percentage of the budget going to cabling. However, up to 80 percent of network problems, which manifest themselves as other problems in the application, can be traced back to cabling. The tendency to correct issues is to go after a simplest approach possible…This can cause waste in capital budgets as unneeded device replacement occurs.
The other thing to notice here is the turnover on equipment vs. the physical layer cabling infrastructure…a company may upgrade networking equipment 4-5 times over the life of the cabling infrastructure, it pays to be forward looking when planning the cabling used.
80% of network problems are caused by only 7% of invested budget.

6. Turning Vision into a Reality …
… that Achieves Benefits:
Navigating
Network
Architectures
Ensure performance, uptime and productivity
Build reliability, reduce troubleshooting time
Ease integration with a standards based approach that is modular and scalable
Reduce cost and time to production
Knowing Where to Start
with Physical Design
Building a standards based roadmap to reduce risk and ease company-wide adoption
So for the rest of the presentation we are going to switch gears a bit to outline some steps in turning your network vision into reality…a primer for the physical design in the industrial network.
We’ll touch on physical design considerations from the logical network requirements and network assessments
Reviewing a standards based approach to the physical design…and how they relate to the network requirements
And providing a starting point with the physical design

7. Translating Logical-to-Physical Design
The Logical network architecture must align with the physical infrastructure design to provide the maximum benefits… to reduce operating costs, speed new hardware implementation, and support future growth requirements
Rockwell Automation and Cisco
Logical Architecture +
Panduit Advisory Services
Physical Design =
Reliable, Scalable, Upgradeable Design
Translate
into Design
Taking Design Phase for granted =
Feature: We Translate the client logical network architecture into a robust physical infrastructure design
Benefit: Optimizes your physical infrastructure based on network requirements, using industry standards and best practices to enhance the efficiency, reliability, scalability, and agility of your facility, and to lower your capital costs
Optimizes your physical infrastructure based on network requirements, using industry standards and best practices to enhance the efficiency, reliability, scalability, and agility of your facility, and to lower your capital costs

8. Agenda
Connected Enterprise: Is your plant ready?
Assessing the Plant Network
Designing the Physical Network
Case Studies and Resources

9. Assessment Number of Connections Today Next 10 years Downtime Cost
How Critical is the Network?
Drives Resiliency, Hardening and Recovery
Bandwidth Consumers
Data Video Control
Walk Through
Cable Distances
Environment
Obstructions
Security
Control Physical and Electronic Access
How do you make an assessment? Start with the most basic. Count up all the devices that need to be connected. This could be machines, sensors, controllers, cameras, drives, switches. You need to plan for today and the next 10 yrs.
Then look at the network traffic volume, type (data, video, control, VOIP) and time criticality for process control. This will lead to bandwidth requirements.
Walk through the plant and envision how to run cable, how harsh is the environment, are there any obstacles.
Lastly, work with manufacturing operations to establish an agreed upon expected network availability. How critical is the network for operations? How much does downtime cost.

10. IntraVUE™ – Industrial Network Visualization and Analytics Software

11. Proven to Be Effective in Identifying:
Duplicate IP and MAC addresses
Intermittent losses caused by noise or vibration
Devices starting to degrade in performance
Accidental loops in cabling located in remote electrical enclosures
Foreign devices connecting to the network (contractor Laptops)
Periodic shorts bursts of broadcast traffic triggered by other devices
Devices accidentally moved to a different port
Cable and connector problems based on crushed, bent, or improperly grounded cable
Redundancy failures using Ring or RSTP
Communication module lockups or failures based on power surges
Non-compliant device Replacement
The issues that happen in an automation network create greater problems as the equipment is reliant on real time performance. Short disruptions can cause equipment or applications to shut down. Issues can be intermittent and momentary, most systems include a variety of different control AND network vendor products making diagnosis with conventional IT tools difficult.

12. A side-bar will pop out with all details on that device
IntraVUE
Clicking on a device will highlight that device and its immediate family
A side-bar will pop out with all details on that device

13. Mobile Network KPI System
Operations Management
Controls & Manufacturing IT
A brand new feature now available to IntraVUE is the management interface. The interface provides management with the other end of the spectrum by producing a summarized daily KPI report that in an instant, will identify to controls and management the condition of their network, and give them data to identify whether they need to spend resources resolving any issues.
Daily KPI Screens can be accessed by Computer or Portable device from IntraVUE

14. Industrial Network Infrastructure Services
Assess
Physical Infrastructure Evaluation
Grounding & Bonding Assessment
In-depth Infrastructure Assessment
Network Visualization
Design
Industrial Networking
Physical Infrastructure Design
Deploy
On-site Project Management
Installation Specification
Deployment Oversight and Validation
Deployment services ensure that design goals become reality. We can help reduce deployment and implementation costs from 20-30%
We provide project management, contractor oversight, progress tracking & status, submittal reviews, issue reconciliation and technical support
Infrastructure Assessment and Optimization Project Management
Benefits of Advisory Services
Evaluate current infrastructure
Apply design best practices, industry standards, and reference architectures
Develop optimal physical infrastructure that will:
Minimize risk
Increase flexibility
Deliver maximum performance
Return on Investment
Optimize agility, scalability, and reliability of current infrastructure for today and the future
Well thought out designs and expertise in connectivity
Support on-time deployment through project management services

15. Agenda
Connected Enterprise: Is your plant ready?
Assessing the Plant Network
Designing the Physical Network
Case Studies and Resources

16. What is an Industrial Automation Reference Architecture?
A framework that describes the relationships between network components.
A example for users on how to deploy.
Central Computer Management Level
Local Control System
Sensors Analyzers
Field Devices
Control Computers
Operator Station
Server
DMZ Server
Enterprise Control Level
Process Control Level
Field Level
Industrial Ethernet
Control Network
Device Network
Office Ethernet
A Reference Architecture is the fundamental organization of a system, the relationships between its components and the environment, and the principles governing its design and evolution. Architectures provide customers with a framework for optimizing their technical resources in support of their business and technical requirements. For example, how do I integrate the Automation and Control data into the Enterprise yet maintain the deterministic qualities of the network? The Ethernet and Internet Protocol suite offer a wide variety of tools and options to implement a network, not all of which are applicable or needed in an Automation and Control network. A Network Reference Architecture for Automation and Control will provide:
• A framework describing the relationship between components of an Automation and Control network.
• A set of principles to guide the design and implementation of the network infrastructure
• Design and implementation material to guide users in the deployment of standard networking
technologies that support EtherNet/IP based systems.
A Reference Architecture should incorporate the knowledge and experience from both the IT and Production Control to outline a solution that optimally applies standard networking technologies that meet the stringent requirements of Automation and Control systems. The Reference Architecture should bring Production and IT together and focus them on one solution that will meet both their different requirements.

17. Converged Plantwide Ethernet (CPwE)
Enterprise Zone
IN-FRASTRUCTURE™
Cell/Area Zones
HMI
DRIVE
L2S
CTRLR
DIST I/O
IN-PANEL™
IN-ROOM™
L3R
L3S
PaS DB
Manufacturing Zone
FWA
FWB
DMZ
IN-ROUTE™
Zone Enclosure
IN-FIELD™
L2S
DEVICE
I/P
IN-Solution Reference
This slide finally takes the Logical Reference of Rockwell and Cisco and applies “PHYSICAL” products to the solution

18. Converged Plantwide Ethernet Architecture
Wide Area Network (WAN)
Physical or Virtualized Servers
ERP - Business Systems
, Web Services
Security Services - Active Directory (AD), Identity Services (AAA)
Network Services – DNS, DHCP
Call Manager
Enterprise
External DMZ/
Firewall
Enterprise
Enterprise Zone Levels 4 and 5
Enterprise Cabinet Solutions
External DMZ/
Firewall
Industrial
Demilitarized Zone (IDMZ)
Plant Firewalls
Active/Standby
Inter-zone traffic segmentation
ACLs, IPS and IDS
VPN Services
Portal and Remote Desktop Services proxy
Physical or Virtualized Servers
Patch Management
AV Server
Application Mirror
Remote Desktop Gateway Server
Micro Data
Center
Industrial Zone
Levels 0–3
(Plant-wide Network)
Remote Access
Server
Active
Standby
Wireless
LAN Controller (WLC)
RADIUS (AAA) Server
Remote Access
Server
Active
Standby
Wireless
LAN Controller (WLC)
RADIUS (AAA) Server
Core
Switches
Distribution Switch Stack
Distribution Switch Stack
Industrial Network Distribution
Cell/Area Zone
Levels 0–2
Physical or Virtualized Servers
FactoryTalk Application Servers and Services Platform
Network & Security Services – DNS, AD,DHCP, Identity Services (AAA)
Storage Array
Level 3 – Site Operations
(Control Room)
Distribution Switch Stack
Cell/Area Zone
Levels 0–2
Phone
Controller
Camera
WGB
LWAP
SSID
5 GHz
Zone Network System
Zone Network System
HMI
Rockwell Automation
Layer 2 Access Switch
Stratix 5000/8000
Soft Starter
I/O
Instrumentation
Controller
LWAP
SSID
2.4 GHz
Drive
Safety Controller
Robot
Safety
Servo AP
5 GHz
WGB
LWAP AP
HMI
Camera
LWAP
LWAP
SSID
2.4 GHz
Rockwell Automation
Layer 2 Access Switch
Stratix 5000/8000
SSID
5 GHz
Safety Controller
Phone
Safety
I/O
WGB
SSID
5 GHz
Soft Starter
WGB
WGB
Control Panel Best Practices
Drive
Controller
Instrumentation
I/O
Servo
Drive
HMI
Controller
Controller
Robot
Safety
I/O
Cell/Area Zone - Levels 0–2 Redundant Star Topology - Flex Links Resiliency
Unified Wireless LAN
(Lines, Machines, Skids, Equipment)
Cell/Area Zone - Levels 0–2 Ring Topology - Resilient Ethernet Protocol (REP)
Unified Wireless LAN
(Lines, Machines, Skids, Equipment)
Cell/Area Zone - Levels 0–2 Linear/Bus/Star Topology
Autonomous Wireless LAN
(Lines, Machines, Skids, Equipment)
CPwE is a
Is a collaborative effort of Cisco Systems, Inc. and Rockwell Automation and now Panduit – filling the physical infrastructure gap.
An architecture that provides network services to Industrial Automation Control Systems (IACS) devices and equipment,
Securely integrates into the wider enterprise network
Panduit is now part of the CPwE to fill the physical infrastructure gap
Panduit thought leadership Included in 4 Appendices part of Resiliency Cisco Validated Design (CVD) part of CPwE
Defines a framework for the IACS devices, equipment, and basic network services based on the Purdue Model for Control Hierarchy
Strict traffic segmentation to protect IACS applications from external and internal interruptions.
Because of the different security requirements of the different levels, an Industrialized Demilitarized Zone (IDMZ) was established. Access to the IDMZ and below is highly controlled (Note: DMZ now IDMZ)
Levels 4-5 of the Enterprise Zone are similar to traditional enterprise networks and have similar availability requirements although.
Enterprise Data Center Pre-configured, Integrated Solutions - Server, switch, MDF (Main Distribution Frame) cabinets
Micro / Industrial Data Center Enterprise to Plant Floor Convergence
Industrial Distribution Frame High Density Distribution
Network Zone System Robust, Secure, Scalable Network Distribution
Control Panel Solutions Mitigate EMI Noise Risk, Save Space & Optimize EtherNet/IP Connectivity
Benefit: Optimizes your physical infrastructure based on network requirements, using industry standards and best practices to enhance the efficiency, reliability, scalability, and agility of your facility, and to lower your capital costs
Optimizes your physical infrastructure based on network requirements, using industry standards and best practices to enhance the efficiency, reliability, scalability, and agility of your facility, and to lower your capital costs

19. Applicable Industrial Standards Telecommunications Standards
ANSI/TIA-1005 is explicitly supported by the 568-C cabling standard
TIA/EIA-568-C Defines cabling types, distances, connectors, cable system architectures, cable termination standards and performance characteristics, cable installation requirements and methods of testing installed cable
C.0 defines the overall premises infrastructure for copper and fiber cabling
C.2 addresses components of the copper cabling system
C.3 addresses components of fiber optic cable systems
ANSI/TIA-568-C.0
(Generic)
TIA-569-B
(Pathways and spaces)
ANSI/TIA-606-A
(Administrative)
ANSI/TIA-607-B
(Bonding and grounding / earthing)
ANSI/TIA-758-A
(Outside plant)
ANSI/TIA-862
(Building automation systems)
ANSI/TIA-568-C.1
(Commercial)
ANSI/TIA-570-B
(Residential)
ANSI/TIA-942
(Data centers)
ANSI/TIA-1005
(Industrial)
ANSI/TIA-1179
(Healthcare)
ANSI/TIA-568-C.2
(Balanced
twisted-pair)
ANSI/TIA-568-C.3
(Optical fiber)
ANSI/TIA-568-C.4
(Coaxial)
Common Standards
Premises Standards
Component Standards

20. Industrial Premises Telecommunications Standards TIA-1005
Developed by the TIA TR-42.9 Industrial Infrastructure Subcommittee and published in May 2012, the Standard provides infrastructure, distance, telecommunications outlet/connector configuration, and topology requirements for cabling deployed in industrial environments.
Industrial Areas
Telecommunications Spaces
Telecommunications Pathways
Firestopping
Backbone Cabling
Horizontal Cabling
Work Area
Grounding and Bonding
Industrial Cabling Performance Requirements

21. Environmental Focus – M.I.C.E.
M.I.C.E. provides a method of categorizing the environmental classes for each plant Cell/Area zone
This provides for determination of the level of “hardening” required for the network media, connectors, pathways, devices and enclosures
The MICE environmental classification is a measure of product robustness:
Specified in ISO/IEC 24702
Part of TIA-1005 and ANSI/TIA-568-C.0 standards
The MICE environmental classification is a measure to assess environment to specify products with suitable robustness
specified in ISO/IEC 24702
part of TIA-1005 and ANSI/TIA-568-C.0 standards
Classifications of MICE
Mechanical
Ingress
Climatic/Chemical
Electromagnetic
Examples of rating:
1585 Media : M3I3C3E3
M12: M3I3C3E3
RJ-45: M1I1C2E2

22. Easy Building Block Approach Utilizing Structured Cabling
Design your system using cost effective and easy to troubleshoot Network Architecture
Copper
Fiber or Copper
Copper
Copper
Once you have determined the design of your Industrial Data Center
Then its how do I get it connected to the field.
Typically fiber connects the zone to the center
Copper connect the Zone to the field instruments.
Installing and Tagging all appropriately with provide the necessary assurances that your physical layer is secure and reliable while being easily modified and configurable.
Leverage Reference Architecture & Validated Building Blocks
to Speed Deployment and Reduce Risks
IN-Room Industrial Data Center
IN-Route Integrated Zone
IN-Field/IN-Panel Control Panel Solutions

23. Zone Architecture Benefits
Traditional Cable Deployment
Node to network room “home runs”
Zone Architecture
Reduced installation time
Simplified diagnostics
Zone architecture design is an efficient way to manage the ever increasing use of ethernet networks on the factory floor. This method shown on the right is designed to organize the network structure based on environmental concerns. When the network is set up this way cabling can be run in proper routing media for that environment. The centralized method is costly and is inefficient when factory reconfiguring occurs.

24. Zone Architecture on the Shop Floor
Control
Panel
Control
Panel
Micro
Data
Center
Zone
Enclosure

25. Target Applications Fiber can be Deployed at All Levels of the Industrial Network
Fiber that fits both the Environment and the Application
Use this slide to show physically how Fiber passes though each of the 5-IN spaces.
Mention that each network segment has different application requirements as well as different MICE requirements and that choosing a fiber is not a one-size-fits-all process. This sets the stage for the rest of the presentation on proper fiber selection.
This is also a nice graphic to show the purpose of our different MDC and Zone Solutions.

26. Industrial Distribution Frame
CPwE
Distribution Switch Stack
HMI
Cell/Area Zone - Levels 0–2 Redundant Star Topology - Flex Links Resiliency
Unified Wireless LAN
(Lines, Machines, Skids, Equipment)
Cell/Area Zone - Levels 0–2 Linear/Bus/Star Topology
Autonomous Wireless LAN
Industrial
Demilitarized Zone (IDMZ)
Enterprise Zone Levels 4 and 5
Rockwell Automation
Layer 2 Access Switch
Stratix 5000/8000
Industrial Zone
Levels 0–3
(Plant-wide Network)
Switches
Core
Phone
Controller
Camera
Safety Controller
Robot
Soft Starter
Cell/Area Zone - Levels 0–2 Ring Topology - Resilient Ethernet Protocol (REP)
I/O
Enterprise
Safety
Drive
Servo
Instrumentation
Level 3 – Site Operations
(Control Room)
External DMZ/
Firewall AP
5 GHz
SSID
WGB
LWAP
2.4 GHz
Cell/Area Zone
Levels 0–2
Remote Access
Server
Active
Standby
LAN Controller (WLC)
Wireless
RADIUS (AAA) Server
Industrial Distribution Frame
Micro Data
Center
Zone Network System
CPwE is a
Is a collaborative effort of Cisco Systems, Inc. and Rockwell Automation and now Panduit – filling the physical infrastructure gap.
An architecture that provides network services to Industrial Automation Control Systems (IACS) devices and equipment,
Securely integrates into the wider enterprise network
Panduit is now part of the CPwE to fill the physical infrastructure gap
Panduit thought leadership Included in 4 Appendices part of Resiliency Cisco Validated Design (CVD) part of CPwE
Defines a framework for the IACS devices, equipment, and basic network services based on the Purdue Model for Control Hierarchy
Strict traffic segmentation to protect IACS applications from external and internal interruptions.
Because of the different security requirements of the different levels, an Industrialized Demilitarized Zone (IDMZ) was established. Access to the IDMZ and below is highly controlled (Note: DMZ now IDMZ)
Levels 4-5 of the Enterprise Zone are similar to traditional enterprise networks and have similar availability requirements although.
Enterprise Data Center Pre-configured, Integrated Solutions - Server, switch, MDF (Main Distribution Frame) cabinets
Micro / Industrial Data Center Enterprise to Plant Floor Convergence
Industrial Distribution Frame High Density Distribution
Network Zone System Robust, Secure, Scalable Network Distribution
Control Panel Solutions Mitigate EMI Noise Risk, Save Space & Optimize EtherNet/IP Connectivity
Benefit: Optimizes your physical infrastructure based on network requirements, using industry standards and best practices to enhance the efficiency, reliability, scalability, and agility of your facility, and to lower your capital costs
Optimizes your physical infrastructure based on network requirements, using industry standards and best practices to enhance the efficiency, reliability, scalability, and agility of your facility, and to lower your capital costs

27. Industrial Data Center (IDC)
Collaboration with industry leaders
Virtualization on the plant floor utilizing the Panduit Micro Data Center with hardware and software from Rockwell Automation, Cisco and other industry leaders
IT-OT Trusted Design
Built to IT industry standards and industrially hardened for the plant
Assembled following robust physical infrastructure best practices, including cable management, thermal design and system grounding
Uptime Reliability
Improve application availability with fault tolerance and automated fault recovery
Easy installation and deployment
Rockwell Automation services included for design consulting, onsite implementation and streamlined support
Rockwell Automation Offering

28. IDF Offering Wall mount, dual hinged, UL Type 4, IP66 26U IDF IDFs
48"H x 24"W x 31"D
Dimensions
24"H x 24"W x 31"D
26U
Rack Units
12U
Up to 3
Copper based Switches
Up to 2
Fiber based Switches 5
Max Switches 2 1
UPS or PDU
Protects 19” rack mount fiber based and copper based switches on the factory floor.
Best in class thermal solution with highest cooling capacity in industry
Wall mount, dual hinged, UL Type 4, IP66.
Provides flexibility with steel or stainless steel option.

29. Integrated Network Zone System
Panduit Offering
Integrated Network Zone System
Dielectric Conduit-ted Fiber Distribution Cable
DIN mount enclosure to break out and protect buffered fibers
Fiber Panel to create testable permanent links on distribution cable
LC to LC Jumpers to Ethernet Switch uplink
Copper patch panel and horizontal cable distribution

30. Thank You! Questions?