With Ethernet-APL, digital process control is finally becoming the new standard in the process industry. The field switches from Pepperl+Fuchs have already proven their durability in a fourth scaling test.
In full swing: Technical experts from end users and manufacturers test scenarios with almost 240 field devices on a redundant control system with very positive results.
(Source: Pepperl+Fuchs)
According to the company, this test was primarily focused on the reliability of Ethernet-APL in extreme situations. However, it was also about the smooth interaction of infrastructure components from different manufacturers. A realistic scenario was played out, which probably corresponds most closely to the reality encountered in process control today. All sensors and other infrastructure components involved in this test have proven their performance capability even under extremely demanding conditions, adds the firm.
The requirements for the scaling test were defined by the chemical company BASF and correspond to a typical application profile for the industry. A total of almost 240 measuring devices were included in the test environment. The flow, pressure, temperature and level sensors, as well as the positioners, came from leading manufacturers such as Endress+Hauser and Samson, explains the company.
Reliability taken to the limit
All field devices were operated via an Emerson Delta V DCS process control system with Profinet system redundancy (S2) and an AMS Device Manager system. Several Ethernet APL field switches from Pepperl+Fuchs ensured signal distribution within a ring-shaped topology and the integration of the parallel Ethernet structure, opines the firm.
A test configuration of this size goes far beyond the usual test setups. The aim here is to explore the limits and prove that Ethernet-APL can also cope with the conditions of an extensive control system in which more than ten thousand signals have to be processed. The aim is to prove that the network and the Delta V control system used here are capable of handling the considerably higher data volume that a maximum number of field devices entail, mentions the company.
Switches in an absolute stress test
The Pepperl+Fuchs switches performed their task with flying colors. Reliability and performance knew no limitations during the entire process. Important performance characteristics such as redundancy switching times and the general network load under the test conditions were met or even exceeded at all times, claims the firm. Cyclical communication - i.e. the transfer of measured and set values between the controller and the field devices - remained stable even in these simulated stress situations.
The test routines also included the overloading of the Ethernet network combined with storm attacks on the switches and field devices, introduced by a separate computer into the network. In practice, an automation system must be able to withstand such situations, even if they occur only in an extremely critical operating state of the system.
This showed the general advantage of the way in which an Ethernet-APL switch communicates with the connected field devices. There are absolutely robust point-to-point connections that remain free from all external influences in every situation. The switch contains special communication filters that provide special protection for the field devices.
Redundancy switching in the Ethernet ring is a standard feature of an Ethernet-APL configuration. This enables network architects to set up a highly available infrastructure with manageable effort, which maintains uninterrupted operation even in the event of unforeseen disruptions, shares the company.
Together towards a new standard
Ethernet-APL is not a proprietary solution. It was not developed by a single supplier. Rather, Ethernet-APL is the result of many years of result-focused collaboration between end users such as BASF and various leading manufacturers from the process sector. Pepperl+Fuchs was also significantly involved in the development and standardization of this technology.
This provides the best conditions for an open system. The market appreciates this and sees it as a strong signal on the way to digitalizing process instrumentation. It is therefore safe to assume that Ethernet-APL offers precisely the advantages that the process industry has been waiting for a long time, opines the firm.
What's more, Ethernet-APL is not only based on existing standards and infrastructures, thereby protecting existing investments. The new network solution also takes much of the complexity out of the automation system. And it does so over the entire life cycle, from conception and implementation through all the way to ongoing operation, explains the company.
Date: 08.12.2025
Naturally, we always handle your personal data responsibly. Any personal data we receive from you is processed in accordance with applicable data protection legislation. For detailed information please see our privacy policy.
Consent to the use of data for promotional purposes
I hereby consent to Vogel Communications Group GmbH & Co. KG, Max-Planck-Str. 7-9, 97082 Würzburg including any affiliated companies according to §§ 15 et seq. AktG (hereafter: Vogel Communications Group) using my e-mail address to send editorial newsletters. A list of all affiliated companies can be found here
Newsletter content may include all products and services of any companies mentioned above, including for example specialist journals and books, events and fairs as well as event-related products and services, print and digital media offers and services such as additional (editorial) newsletters, raffles, lead campaigns, market research both online and offline, specialist webportals and e-learning offers. In case my personal telephone number has also been collected, it may be used for offers of aforementioned products, for services of the companies mentioned above, and market research purposes.
Additionally, my consent also includes the processing of my email address and telephone number for data matching for marketing purposes with select advertising partners such as LinkedIn, Google, and Meta. For this, Vogel Communications Group may transmit said data in hashed form to the advertising partners who then use said data to determine whether I am also a member of the mentioned advertising partner portals. Vogel Communications Group uses this feature for the purposes of re-targeting (up-selling, cross-selling, and customer loyalty), generating so-called look-alike audiences for acquisition of new customers, and as basis for exclusion for on-going advertising campaigns. Further information can be found in section “data matching for marketing purposes”.
In case I access protected data on Internet portals of Vogel Communications Group including any affiliated companies according to §§ 15 et seq. AktG, I need to provide further data in order to register for the access to such content. In return for this free access to editorial content, my data may be used in accordance with this consent for the purposes stated here. This does not apply to data matching for marketing purposes.
Right of revocation
I understand that I can revoke my consent at will. My revocation does not change the lawfulness of data processing that was conducted based on my consent leading up to my revocation. One option to declare my revocation is to use the contact form found at https://contact.vogel.de. In case I no longer wish to receive certain newsletters, I have subscribed to, I can also click on the unsubscribe link included at the end of a newsletter. Further information regarding my right of revocation and the implementation of it as well as the consequences of my revocation can be found in the data protection declaration, section editorial newsletter.
For example, the user has access to communication and diagnostic information via an easy-to-use web interface on the Ethernet-APL field switch. This enables even less specialized employees to set up and commission a communication system without in-depth knowledge or special tools. The device data can also be integrated into the asset management system. This seamlessly accessible information and its integration into higher-level systems is part of a concept of general simplification and is to a certain extent one of the genes of Ethernet-APL.
Interaction without compromise
BASF explains that with the help of digital field devices, they were able to optimize various topics relating to engineering, commissioning and lifecycle in BASF plants and reduce Capex and Opex costs.
For Endress+Hauser, the scaling test is one of four similarly designed tests that have proven beyond doubt that Ethernet-APL is ready for widespread use in the process industry.
Ethernet-APL offers decisive prerequisites for making a process plant more transparent down to the individual field device than was possible with previous analog technologies. This digital technology makes a decisive contribution to realizing more efficient and cost-effective industrial automation systems. It is the technological door opener for a wealth of new applications that were simply not possible before, shares the company.
Ethernet-APL already is the core of a broad ecosystem that more and more manufacturers of infrastructure components are joining. The first successful implementations are creating trust and show that Ethernet-based communication in process automation is on the rise.
Ethernet-APL has what it takes to become a standard, especially in the process sector with its often highly critical applications.
Pepperl+Fuchs encourages planners and end users to familiarize themselves with Ethernet-APL and the integration technologies with the help of a test setup or a small installation and to exploit the advantages, concludes the firm.