Managing device diversity for operational continuity and performance at field level

Industry 4.0 prioritized the digitalization of plants, alongside rapid developments in sensors, IoT and evolving process control. This is a significant step towards autonomous operations and has brought with it many lasting benefits but has also created a number of challenges for plant owners. As process plants work towards becoming more connected, automated and intelligent, one of these challenges is ensuring secure access to critical data across expanding fleets of field devices and equipment. 

These are often made up of many instruments or devices that have been added over time. The differences in levels of connectivity and the separate tools, protocols or workflows required for the retrieval of data and critical information makes management of these fleets the challenge. The result is added complexity in day-to-day operations, creating greater difficulty in achieving consistent visibility, timely diagnostics and integrated control within the plant.

From sensors and control valves to safety system components, motor controls and switchgear, a plant that has been operating for decades may have accumulated layers of instrumentation or equipment with very different capabilities. Earlier devices using simple analog signals are installed alongside smart instrumentation offering the latest digital communication, using wireless networks and are equipped with advanced diagnostic capabilities. Together they form a fragmented landscape, with each requiring different management methods that can be difficult to orchestrate.

A single plant may be instrumented with mA instruments and actuators, HART-enabled devices, low speed fieldbus devices (Profibus PA or FOUNDATION Fieldbus) and wireless sensors or new APL instruments, each with different management requirements. Technicians must combine diverse skills and access fragmented records, while calibration data may be scattered across logbooks, spreadsheets or disconnected systems. The result is incomplete visibility, longer downtime in case of device replacement more reactive maintenance and greater difficulty in meeting safety and environmental standards as experienced engineers retire and knowledge of legacy systems disappears.

Towards structured field information management

The answer to the problem lies in the development of field information strategies which focus on unifying access, monitoring and management across a plant’s installed base of equipment, devices and instrumentation, regardless of generation or source. 

Using specialized field information software to deploy these strategies simplifies the configuration, commissioning, diagnostics and maintenance of field instruments, particularly those using fieldbus technologies. The software together with secure access to the automation system via an Edge device that ensures dataflow integrity and protection, serves as a bridge between information technology (IT) and operational technology (OT), enabling data-driven decision-making and enhancing operational efficiency.

In practical terms, this involves creating a central dashboard where information integrated with existing control systems can be accessed, allowing lifecycle-based views of asset health and performance. Modern field information strategies also incorporate advanced analytics, enabling pattern recognition across device populations and supporting predictive maintenance that can identify potential failures before they occur.

Beyond ongoing maintenance, structured field device management strategies also transform commissioning. Bulk device configuration, template-based parameterization and centralized diagnostics can reduce start up times significantly while lowering the risk of errors. When directly integrated with the distributed control system (DCS), these capabilities shorten commissioning, ensure consistent handover into operations and strengthen resilience from the first day of operation. Once in operation, integrated field data feeds directly into the automation ecosystem enabling monitoring and optimization on digital Level 3 applications or directly in the control environment. This allows tighter process optimization and faster operator response to changing conditions. The connection between device, DCS and digital layer strengthens both efficiency and resilience from day one.

When deployed across the plant, this enables engineers to shift from reactive, fragmented practices to more predictive, standardized methods of management. Implementation often begins with pilot projects in critical process areas, allowing procedures to be refined before extending across a full fleet.

Importantly, these strategies are designed to map information across both older and newer equipment, ensuring continuity of operations while supporting a gradual move towards more predictive performance. This compatibility protects existing infrastructure investments while providing a clear pathway for future enhancements.

Unlocking performance through visibility

By providing clear visibility of device and system behavior, field information strategies enable online condition monitoring, plant-wide analytics, effective collaboration and a pathway towards greater autonomy, all of which directly enhance performance.

One of the most important performance gains is the ability to monitor equipment condition online. This is particularly valuable in brownfield environments where equipment age, installation practices and documentation vary widely. With unified access to diagnostic data, operators can move beyond time-based maintenance and assess condition based on live operating information. This allows for faster, better-informed decisions, improving process reliability and minimizing downtime.

Broader system visibility can be achieved by combining field data with plant-wide analytics. Trends can be tracked over time, issues flagged early and maintenance prioritized based on actual need. Analytics can also identify correlations between different types of equipment, uncovering performance patterns that may otherwise go undetected.

These insights support more precise process control within the DCS environment. By understanding how actual equipment performance varies from expected parameters such as accuracy, drift or signal noise, operators can make timely adjustments that improve quality, reduce waste and enhance responsiveness.

Shared digital views also strengthen collaboration between operations and maintenance teams. Replacing isolated checks and disparate records with a common data environment improves communication, helps clarify root causes and reduces unnecessary interventions.

Extending lifecycle value from the installed base

Field device management strategies support performance not only in running operations, but across the full lifecycle of an asset, from commissioning and configuration through to maintenance, upgrades and modernization.

Correct data management across all generations and types of devices ensures better-informed decisions throughout the asset lifecycle. By consolidating calibration records, device settings and diagnostic histories into a unified system, it becomes easier to assess asset health, manage risk and plan changes based on actual performance.

Lifecycle value is also increased through improved commissioning. Bulk device configuration, template-based setup and centralized diagnostics reduce start-up time, ensure consistency and minimize the risk of human error. When this data is integrated directly into the DCS, it strengthens operational readiness from day one.

The risk of unplanned downtime can be reduced through continuous access to accurate diagnostics, which enables predictive maintenance which in turn supports compliance with safety and environmental regulations.

This enables plant owners to update their systems and fleets over time, introducing new technologies where needed without compromising operational continuity.

As plants move towards higher levels of autonomy, structured data enables greater agility while ensuring operators retain full visibility and control. The same data that informs today’s maintenance decisions can support tomorrow’s automated strategies, aligning operational expertise with evolving automation goals.

Conclusion

To summarize, addressing device diversity through field device management is central to sustaining operations and preparing for greater autonomy. When information from the field layer is captured in a consistent, contextualized way it provides a common foundation for decisions across the lifecycle. 

Commissioning, optimization and predictive maintenance can then be approached not as isolated tasks but as connected stages of a longer continuum. This delivers faster commissioning with fewer errors, simpler diagnostics and maintenance that reduce downtime, clearer visibility of asset condition and a traceable configuration history that supports compliance and staged modernization. In doing so field device management strategies turn the challenge of diversity into a means of sustaining continuity today while building the resilience required for the next stages of digitalization and automation.