The OT Crowd

Jarie Bolander, David DeBari, & Andrew Vanderpool
  • 0.0 (0)
  • Technology

Break room talk, not a briefing. Proprietary automation economics are hitting a wall. Closed control systems lock plants into one vendor's roadmap, pricing, and upgrade cycle, and every modernization turns into a rip-and-replace bet. Open Process Automation (OPA) changes the math. It decouples hardware, software, and lifecycles so plants can upgrade piece by piece, mix vendors, and own their architecture. The OT Crowd digs into what that means for the plant floor, the budget, and everyone who builds, sells, and runs these systems. Jarie asks the questions you're thinking. David and Andrew tell you what's really going on. David is the OT veteran who has seen the field cycles, the vendor lock-in, and the migration that almost went sideways. Andrew co-chaired the Open Process Automation Forum's Technical Working Group and came up on the I/O vendor side, so he knows how O-PAS gets written (and argued over) and what it takes to ship into an open stack. Each episode brings in operators, integrators, and standards people to dig into open control, O-PAS, plant-floor problems, and how the industry markets and sells it all. No hype. No brochure. Just honest conversation worth your commute. New here? Start with our five-part series, What Is OPA?, which covers why OPA matters, what it is (and isn't), and how the architecture works. Think you can stump us? Send your question at theotcrowd.com/stump-the-hosts A CPLANE production.

Episodes

  1. 6d ago

    E07: High Availability Demo on an OPA System

    High availability is not just redundancy with a new label. It is the difference between a system that survives failure and a system that keeps the plant running through patching, device swaps, and real-world downtime pressure. Jarie Bolander is joined by Andrew and David DeBari for a live, slightly chaotic demo of an OPA-based high availability setup that shows what modern industrial automation can actually do when hardware, software, and networked control are designed to work together. They break down why the OPA Forum extended the OPC UA high availability story, where the spec was still too vague for vendors to implement consistently, and how the latest informative additions to Part 4 help close those gaps. Andrew explains the difference between redundancy and true high availability, including why one-to-one models are only the beginning and why scan-cycle takeover matters. David puts the business and operations case in focus, showing how process industries need more than failover - they need systems that can handle maintenance, lifecycle events, and uninterrupted production. You’ll discover: Why high availability is more powerful than classic redundancy How leader-follower control can shift across multiple DCNs Why one device can take over in the very next scan cycle How HA supports patching, upgrades, and hardware replacement without planned downtime Why OPA opens the door to mixing hardware, software, and even virtual controllers The demo makes the architecture tangible: a live process simulation, a ping pong ball held at setpoint, DCN failover, network-only connectivity, and interoperability across hardware and software from multiple vendors. It is a rare look at what open automation looks like when it is actually running, not just promised. If you work in process automation, industrial controls, or OT architecture, this episode shows why HA is becoming a ticket to entry - especially where uptime, safety, and economics leave no room for guesswork. It is also a useful listen if you want to understand how open standards are changing what is possible in industrial systems. Perfect for engineers, architects, and automation teams who need less downtime, more flexibility, and a clearer view of how OPA-enabled high availability really works.

  2. Oct 16

    E06: What is OPA? Part 5

    Open architecture process automation is no longer a theory - it's already running in real plants, real projects, and real product ecosystems. If you're wondering whether OPA is vaporware or a practical path forward for automation, cybersecurity, and future-ready control systems, this episode gives you the clearest answer yet.Jarie Bolander and David DeBari close out their five-part OPA series by showing what has actually been proven in the field and what comes next. They break down why OPA is moving from concept to commercial reality, how it has been deployed at scale, and why standards-based systems are changing the way teams think about control, interoperability, and technology insertion.You'll discover: How OPA moved from R&D into commercial reality through a lighthouse projectWhy ExxonMobil's conversion of a DCS system proved OPA can work at both large and small scalesWhat the ACT project in Baton Rouge demonstrates about competitive bidding and standards-based procurementHow Texas A&M is using COPA systems in small modular reactor research with AI-assisted operator supportWhy interoperability, cybersecurity, and component choice matter more than everThe three key questions to ask before adopting OPA: can you choose components, do you own the system, and can you grow it without ripping and replacing it?David shares firsthand experience from years of OPA R&D and explains why this is not slideware or a future promise - it's production technology that can replace PLC and DCS systems, support HMI, historian, alarming, and SCADA functions, and create a foundation for bringing advanced control and data analysis inside the system instead of bolting them on later.Jarie and David also tackle the practical realities of adoption: what it means to build a business case, why teams need systems that can evolve without waiting years for vendor roadmaps, and how open standards can finally make "the answer is always yes" possible when business needs change.If you want a real-world, no-hype look at where OPA stands today and how to evaluate it for your own operation, this is essential listening. Perfect for automation leaders, control engineers, integrators, and anyone trying to decide whether open process automation belongs in their future.

  3. Oct 16

    EP05: What is OPA? Part 4

    Most people think standards slow innovation down. Open Process Automation proves the opposite - if you get the architecture, cybersecurity, manageability, and conformance model right, interoperability gets easier and proprietary lock-in starts to disappear. Jarie Bolander and David DeBari break down part four of their five-part OPA series, unpacking how the Open Process Automation Forum defines the OPAS specification and why it’s built as a “standard of standards.” They explain the minimum requirements that make a modern automation system actually work across vendors, from IEC 62443 cybersecurity and SL2 protection to Redfish diagnostics, OPC UA communications, and the move toward application portability and orchestration. You'll discover: Why OPA deliberately adopts existing standards instead of inventing new ones How IEC 62443, Redfish, OPC UA, IEC 61131-3, and IEC 61499 fit into the architecture Why value, timestamp, quality, engineering range, and engineering units matter for real-world troubleshooting How conformance testing prevents “open” systems from being open in name only Why third-party certification is essential for true interoperability and vendor trust David also explains the practical pain points that OPA is trying to solve, from scaling errors and unit mismatches to proprietary connectors and one-port hardware that makes redundancy impossible. The result is a clearer picture of how the forum balances innovation with just enough structure to make systems portable, diagnosable, and secure. If you work in automation, industrial control, OT, or industrial software, this episode gives you the framework behind the standard and the reason compliance is the foundation for everything that comes next. Essential listening if you want to understand where OPA is headed and why part five matters.

  4. Oct 16

    EP04: What is OPA? Part 3

    OPA is not a unicorn, it's a computer - and that changes everything. If you work in industrial automation and you're tired of ripping and replacing entire systems every time technology changes, this episode shows why Open Process Automation is built for continuous evolution, not reinvention.Jarie and David break down the architecture behind OPA in plain English, exposing the myth that PLCs and DCSs are magical black boxes. Instead, they show how these systems are really computers with operating systems, applications, network ports, APIs, and security - and why treating them that way unlocks a much more flexible future for OT.You'll discover: Why tightly coupled hardware, software, and I/O create the expensive "rip and replace" trapHow lifecycle mismatches between wiring, I/O, software, and compute drive unnecessary downtimeWhy OPA separates the DCN, OCF network, and ACP to make systems more resilientHow OPC UA and orchestration enable secure onboarding, faster deployment, and easier expansionWhy loosely coupled architecture helps avoid single points of failure and supports better redundancyDavid also explains how OPA borrows the best ideas from IT without ignoring OT realities like safety, momentum, chemistry, and containment. The result is a system designed to keep control, preserve visibility, and protect data even as hardware and software age at different speeds.They also make the business case clear: lower total cost of ownership, more upgrade flexibility, and the ability to say "yes" when the plant needs new capabilities, whether that's a digital twin, advanced analytics, or expanded I/O.Essential listening if you want to understand how OPA architecture actually works, why standards matter, and how industrial systems can finally evolve without forcing a full rebuild every time.

  5. Oct 15

    EP03: What is OPA? Part 2

    Open process automation is more than an acronym - it's a blueprint for breaking vendor lock-in, improving cybersecurity, and making industrial systems easier to change, scale, and trust. In this second part of the OPA mini-series, Jarie and David unpack why a "standard of standards" could reshape how automation gets built and maintained.David, who served on the OPA forum subcommittee and co-led the application portability work, breaks down the core promises behind OPA: interoperability, interchangeability, adequacy, and portability. He explains how the Open Process Automation Standard, or OPAS, pulls together proven standards like OPC UA, IEC 62443, IEC 61131, 61499, and PA-DIM instead of inventing everything from scratch.You'll hear why automation teams spend so much of their lives trying to get A to talk to B, why proprietary form factors create painful warehouse and maintenance headaches, and why portability matters when you want to move engineering work between systems without rebuilding everything from zero. The conversation also gets into the non-negotiables - security, manageability, and reliability - and why cybersecurity has become the watchword in an era of constant breaches and accelerating AI-driven threats.Jarie and David also zoom out to the business impact. If you've ever had to tell leadership "no" because the system couldn't support a new capability, this episode shows how open standards change that equation. Instead of forcing advanced control and new technologies to live outside the system, OPA aims to make innovation part of the architecture itself.Perfect for plant managers, control engineers, automation practitioners, and anyone frustrated by closed systems that slow progress. If you want a clearer picture of how open automation creates more choice, more flexibility, and fewer dead ends, this episode makes the case in plain language.

  6. Oct 15

    EP02: What is OPA? Part 1

    EPISODE DESCRIPTION - Ready to publishUSB-C changed the consumer world by making one standard actually work. What if OT could do the same? In this kickoff to a multi-part OPA series, Jarie, Andrew, and David break down why open process automation could be the long-overdue “USB for OT” - and why that matters for every plant still trapped in proprietary lock-in.Jarie sets the stage for the series, Andrew explains what OPA really is, and David brings the hard-won historical perspective, showing how automation got here and why the old model is no longer enough. Together they make the case for a standards-based, interoperable, secure automation architecture that lets you upgrade and integrate systems without tearing everything apart.You’ll discover: Why OPA is best understood as a “standard of standards”How OPAST, OPAF, and the Open Group fit togetherWhy certification and compliance are becoming non-negotiable in OTWhat USB-C, TCP/IP, fire hydrants, and safety systems have in common with industrial automationHow interoperability and interchangeability reduce costly engineering workaroundsDavid shares what it was like when vendors couldn’t even agree on basic protocols, and how the industry’s “bag of adapters” mentality has kept plants dependent on patching, mapping, and proprietary fixes for decades. Andrew and Jarie keep bringing it back to the real-world payoff: easier upgrades, better choices in hardware and software, and systems that can evolve without ripping and replacing everything when one component disappears.If you work in automation, controls, operations, or industrial cybersecurity, this episode makes the case for why standards are no longer a nice-to-have - they’re the foundation for safer, more flexible, more future-proof systems. It’s a sharp, practical, and surprisingly relatable conversation about why OT needs the same level of plug-and-play sanity the rest of technology already enjoys.Perfect listening if you’ve ever had to make incompatible systems talk, fight through vendor lock-in, or justify why “that’s just how we’ve always done it” is no longer a valid answer.

  7. Sep 28

    E01: Introducing The OT Crowd

    Meet the crowd. Jarie asks the questions you're thinking (and learns out loud). David is the OT veteran who has seen the alarm floods, the vendor lock-in, and the migration that almost went sideways (and knows a thing or two about O-PAS). Andrew co-chaired OPAF's Technical Working Group and came up on the I/O vendor side, so he knows how O-PAS gets written (and argued over). In this first episode, they explain why the show exists: break-room talk about industrial automation, not another vendor keynote. They walk through the format, starting with the five-part What Is OPA? series, followed by guest episodes with operators, integrators, and standards people. They also cover what the show will (and won't) cover.

  • 7 Episodes

About

Break room talk, not a briefing. Proprietary automation economics are hitting a wall. Closed control systems lock plants into one vendor's roadmap, pricing, and upgrade cycle, and every modernization turns into a rip-and-replace bet. Open Process Automation (OPA) changes the math. It decouples hardware, software, and lifecycles so plants can upgrade piece by piece, mix vendors, and own their architecture. The OT Crowd digs into what that means for the plant floor, the budget, and everyone who builds, sells, and runs these systems. Jarie asks the questions you're thinking. David and Andrew tell you what's really going on. David is the OT veteran who has seen the field cycles, the vendor lock-in, and the migration that almost went sideways. Andrew co-chaired the Open Process Automation Forum's Technical Working Group and came up on the I/O vendor side, so he knows how O-PAS gets written (and argued over) and what it takes to ship into an open stack. Each episode brings in operators, integrators, and standards people to dig into open control, O-PAS, plant-floor problems, and how the industry markets and sells it all. No hype. No brochure. Just honest conversation worth your commute. New here? Start with our five-part series, What Is OPA?, which covers why OPA matters, what it is (and isn't), and how the architecture works. Think you can stump us? Send your question at theotcrowd.com/stump-the-hosts A CPLANE production.

Information

  • Creator
    Jarie Bolander, David DeBari, & Andrew Vanderpool
  • Years Active
    2026
  • Episodes
    7
  • Rating
    Clean
  • Copyright
    © 2026 Jarie Bolander, David DeBari, & Andrew Vanderpool
  • Show Website
    The OT Crowd