Power Data-Driven Decisions with Ethernet-APL

In the evolving world of industrial automation, the need for real-time, high-quality data has never been more critical. But getting that data where it needs to go is not always simple. Consider bus technologies. Profibus, HART, Modbus and more all use different cables, interface hardware and data formats. Moreover, each technology has its own strengths and weaknesses, making it almost impossible to select a single solution for all field deployments.

Having multiple bus technologies is frustrating, as it requires teams to support multiple infrastructures. As a result, businesses want a solution to allow them to standardize on a single infrastructure across multiple instruments and devices. Similarly, vendors also seek a single solution—one where each instrument can support many different protocols. Enter Ethernet.

Ethernet, using IP, can handle a wide array of standard protocols at the same time. But, until recently, Ethernet came with its own drawbacks for industrial applications. Traditional Ethernet does not support long cable lengths as the signal quickly starts to degrade. It also requires separate power and is not rated for use in hazardous areas.

That paradigm, however, has changed with the advent of Ethernet Advanced Physical Layer (APL). Ethernet-APL extends innovation in automation, evolving the way organizations approach control and asset management in process industries, enabling next-level connectivity in hazardous areas and opening up more opportunities for efficient plant operations.

For those unfamiliar, Ethernet-APL, as the name suggests, is a physical wire standard that enables industrial protocols to be used in hazardous areas. It brings two major advancements: intrinsic safety for use in explosive environments and the ability to carry power and data over a single twisted-pair cable. This dual capability enables teams to connect field devices, like sensors and actuators, where the data is needed—whether at the edge, at long distances in the field, or in the cloud. These connections bypass the complexities and limitations of traditional communications protocols in favor of advanced protocols such as PROFINET, Ethernet/IP, HART-IP, Modbus TCP and/or OPC-UA.

With Ethernet-APL and these advanced protocols, organizations are not only able to handle high data rates over long distances but can also improve integration with existing IT infrastructure. This means that the detailed data collected from field instruments can seamlessly flow into advanced analytics and asset management platforms. The result? Operators gain deeper insights into equipment health, operational efficiency and process performance—without adding more complexity or costly infrastructure.

Ethernet-APL adoption will likely be very popular in sectors like oil & gas, chemical processing and power generation, where data accessibility in hazardous environments is important. This shift is not just about technology; it is about creating more sustainable, efficient and resilient industrial systems that respond dynamically to change.

The transition to Ethernet-APL will not be immediate. There are still many legacy devices in plants that will need support, and not every one will justify the cost of retrofitting with an Ethernet-APL adapter. However, as innovation drives more devices using massive amounts of bandwidth—high-definition video cameras, for example—Ethernet-APL will commonly be the go-to source for data transmission. As a result, many organizations are building it into greenfield projects and brownfield modernizations to lay a foundation for an increasingly data-intensive future.

The bottom line? Ethernet-APL and advanced digital protocols are redefining what is possible in industrial automation by providing the backbone for smarter, safer and more connected operations. As more companies adopt this standard, process manufacturers will witness an evolution in how they manage and control assets, with data as the driving force.