Microsoft powerpoint - 1823 - PCS 7 Redundancy.ppt

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2008 Automation Summit A Users Conference
ID#: 1823 Title: PCS 7 Redundancy Tailored to Your Needs Topic: Process Automation

Presenter: Christoph Lehmann Company: SE&A

Expand your world of automation

Presenter - Christoph Lehmann
PCS 7 Product Manager in the U.S. Grad. Engineer (Dipl. Ing.) - Electrical Engineering Application Engineer for Automation Systems DCS System Specialist for High Available PCS 7 Pilot Installations System Consultant for Critical Control and Process Safety Systems PCS 7 Product Manager for Process I/Os and Safety Systems
Contact: Christoph Lehmann PCS 7 Product Management USA Phone: +1 (215) 646 7400 ext. 2122 Cell Phone: +1 (267) 421 9327 email: christoph.lehmann@siemens.com Address: SIEMENS Energy & Automation Inc. 1201 Sumneytown Pike P.O. Box 900 Spring House, PA 19477 USA

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PCS 7 Redundancy tailored to your needs
To minimize plant down-time PCS 7 offers well-conceived redundancy concepts which stretch across all automation levels. A unique and extremely flexible system architecture enables costeffective fault-tolerant solutions exactly where they are required. This presentation gives you an overview of fault-tolerant architectures from the instrument level up to the Operator Screens.

Contents: MTBF and Reliability PCS 7 Redundancy concept
- Solutions for OS, AS, I/O, Communication, Fieldbus

Application Notes

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Motivation Why is high availability important? “The plant has to be running!”
Failures of the process control system or of any of its components can lead to a plant shutdown which causes: production loss expenses for activities to restart the process loss of an entire batch due to lost quality data

Goal: Minimize the probability of a production shutdown and the impact of failures!
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Module MTBF – Part Count Method
The module MTBF of SIMATIC components is calculated with the Part Count Method.
The approach is to sum up all component failure rates regardless of the structure according to IEC 61709, SN 29500 and MIL-HDBK-217F Assumption of a serial structure

MTBF1

MTBF2

MTBF3

1 1 1 1 = + + MTBFs MTBF1 MTBF2 MTBF3 MTBFs = 1

λ1 + λ2 + λ3

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Module MTBF – Field Approach
The field approach requires failure rate data from the field, which are gathered by product observation and field data acquisition

Theoretical approach
module MTBF theot.

Field approach

=
<

module MTBF field

MTBF theor.

MTBF field

The field approach serves MTBF values which are > 3 times better than the predicted values

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Module MTBF: Calculated vs. Field
Module
CPU 417-4HL01 Sync Module

MTBF (calc.)
14.9 Years 150.0 Years

MTBF (field)
261.7 2453

Factor
17.6 16.3

http://support.automation.siemens.com/WW/view/en/16818490

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Reliability of the plant
Regarding Reliability, Availability and Maintainability of a process control system, always keep in mind: The process control system1) is only a part of the whole plant. For reliability analysis of a plant, all components have to be taken into consideration:
Pumps and motors Valves Sensors Supplies (air, steam, electric power, …) Cabling Simplified reliability structure:
Plant 2) Process Control System1)
OS Network

1) Controller

Network

I/O-system

Cabling

Supplies

Sensor/ Actuator

1) 2) page 8

mainly our objective is to do a prediction of the DCS system avoid to include this peripheral components ( often not SIEMENS products) in the prediction

Redundancy at all levels with SIMATIC PCS7
Parallel redundancy of OS/Batch clients Redundant OS/Batch servers with archive synchronization between servers Double-redundant plant bus and terminal Bus Fully redundant automation system with optical fiber connection between CPUs Redundant connection of the distributed I/O Redundant connection of PROFIBUS PA Redundant connection of non-redundant PROFIBUS DP devices with Y link Redundant I/O modules Redundant Profibus PA Ultimate flexibility to choose the redundancy levels to fit the application

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Benefits of the SIMATIC PCS 7 redundancy concept
Scaleable solutions throughout the modular system to adapt the system design to the requirements Cost optimized solution Failures of a redundant component will be automatically reported to the operator station Failures are detected without delay. Failed components can be quickly exchanged to restore the redundancy and minimize the meantime to repair. Hardware upgrades for redundancy have minimum impact into the software configuration Minimum effort to upgrade the system architecture

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SIMATIC PCS 7 – Redundancy at all levels
Solutions for the Operator System
WEB Client SIMATIC IT Office LAN (Ethernet) Client Station WEB Server (OPEN PCS 7) OS LAN (Ethernet) OS Server ROUTE Control Industrial Ethernet AS 41x HF ET200M HF ET200S ET200M HF (Standard & F-Modules) ET200M HF ET200iSP CAS/ BATCH Server Engineering/ Maintenance Station

AS 41x PROFIBUS DP

SIMOCODE

ET200iSP

PROFIBUS PA

PROFIBUS DP

PROFIBUS PA

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SIMATIC PCS 7 Redundancy – Solutions for the Operator System
Parallel OS Single Stations

ES

OS

OS

Each station includes all operation and monitoring functions In case of a station failure, all other stations remain available Note: There is no data exchange between the stations, which means that in the case of a failure there is a data gap in the OS Archives (Tags and Events) of the failed station.

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SIMATIC PCS 7 Redundancy – Solutions for the Operator System
Redundant OS Single Stations

ES

OS

OS

Fully Redundant Operator Stations Archive Synchronisation (Messages and Tags) between the OS Single Stations, no gaps in Trends and logs after a PC failure Online Configuration possible while both OS Single Stations run Higher Availability than one Server and one Client

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SIMATIC PCS 7 Redundancy – Solutions for the Operator System
Server-Client-Architecture with redundant servers

A

A

A

B

B

B

Server A

Server B

Initial State: Distribution of the clients between redundant servers A and B (preferred server for each client) Automatic client switchover in case of a HW or SW failure of a OS Server Server recovery: automatic reconnection and automatic archive synchronization Automatic client switching after server recovery (back to initial state: preferred server) In case of a client failure all other clients remain available
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Expandable up to 12 redundant servers and 32 clients/server

SIMATIC PCS 7 Redundancy – Solutions for the Operator System
Central Archive server
Client Stations

OS LAN (Ethernet) OS Server CAS Industrial Ethernet AS 41x HF

AS 41x

Fully Redundant Central Archive Servers Archive Synchronisation (Messages and Tags) between the CAS servers, no gaps in Trends and logs after a PC failure Online Configuration possible while both CAS servers run CAS redundancy is independent of the OS server redundancy

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SIMATIC PCS 7 – Redundancy at all levels
Solutions for the Automation System
WEB Client SIMATIC IT Office LAN (Ethernet) Client Station WEB Server (OPEN PCS 7) OS LAN (Ethernet) OS Server ROUTE Control BATCH Server Industrial Ethernet AS 41x HF ET200M HF ET200S ET200M HF (Standard & F-Modules) ET200M HF ET200iSP CAS Engineering/ Maintenance Station

AS 41x PROFIBUS DP

SIMOCODE

ET200iSP

PROFIBUS PA

PROFIBUS DP

PROFIBUS PA

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SIMATIC PCS 7 Redundancy – Solutions for the Automation System
Redundancy Options

Single System
single power supply single system bus single controller double power supply single system bus single controller double power supply double system bus single controller (H)

H System
double power supply double system bus double controller quad power supply double system bus double controller quad power supply quad system bus double controller

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SIMATIC PCS 7 Redundancy – Solutions for the Automation System
Redundant Controller S7-400H
AS 412 H AS 414 H AS 417 H

Two redundant configured subsystems that are synchronized via fibre optic cables Very fast switchover Hot redundancy: user program is completely identical and is simultaneously executed; results are compared at every output Shared rack or separated rack (for distances up to 6 miles)
6 miles

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SIMATIC PCS 7 Redundancy – Solutions for the Automation System
Redundant Controller S7-400H: Automatic Event Synchronization
Definition Synchronization whenever the two redundant CPUs could end up with different results during execution of the program. Automatic operating system function Synchronizing Events Updating the process image & I/O access Interrupts, alarms Updating timers Changes to program data through communication func. Guarantees bumpless switchover Fast switchover time (typically 30ms) No loss of information No loss of alarms Resumes processing of program where it left off
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(Siemens patent) Event
Synchronization

CPU A

CPU B

SIMATIC PCS 7 Redundancy – Solutions for the Automation System
Redundant Controller S7-400H: FW Update

Improved FW Update for redundant systems: Error correction during operation

Flash Card or New via Ethernet

1. 2. 3. 4.

CPU Update Switch Over CPU Update Coupling

Automatic Change Over

New

As simple as modification during operation

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SIMATIC PCS 7 – Redundancy at all levels
Solutions for I/Os
WEB Client SIMATIC IT Office LAN (Ethernet) Client Station WEB Server (OPEN PCS 7) OS LAN (Ethernet) OS Server ROUTE Control BATCH Server Industrial Ethernet AS 41x HF ET200M HF ET200S ET200M HF (Standard & F-Modules) ET200M HF ET200iSP CAS Engineering/ Maintenance Station

AS 41x PROFIBUS DP

SIMOCODE

ET200iSP

PROFIBUS PA

PROFIBUS DP

PROFIBUS PA

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SIMATIC PCS 7 Redundancy – Solutions for I/Os
Single Controller / Single I/O
Single Controller Single PROFIBUS DP
Fiber Optic and Ring Topology possible
PROFIBUS DP

PROFIBUS Interface (IM 153-2) Single Channel I/O:
Single I/O modules installed in a single Rack

PA devices via DP/PA-Link
DP/PA-Link
PROFIBUS PA

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SIMATIC PCS 7 Redundancy – Solutions for I/Os
Redundant Controller / Single I/O
Redundant Controller Redundant PROFIBUS DP
Fiber Optic and Ring Topology possible
PROFIBUS DP

Redundant Controller

Redundant PROFIBUS Interface (IM 153-2) Single Channel I/O:
Single I/O modules installed in a single Rack connected to a redundant Profibus.

Y-Link

PROFIBUS DP devices via Y-Link
DP/PA-Link

PA devices via redundant DP/PA-Link

PROFIBUS PA

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SIMATIC PCS 7 Redundancy – Solutions for I/Os
Redundant Controller / Redundant I/O
Redundant Controller Redundant PROFIBUS DP
Fiber Optic and Ring Topology possible
Redundant I/O-modules

Redundant PROFIBUS Interface (IM 153-2) Dual Channel I/O:
Redundant I/O Modules can be installed in separated Racks via redundant PROFIBUS DP Redundant Partner Module can be selected by the user Mixture of redundant and non redundant I/O racks on the same controller

PROFIBUS DP

Y-Link

DP/PA-Link
PROFIBUS PA

PROFIBUS DP devices via Y-Link PA devices via redundant DP/PA-Link
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SIMATIC PCS 7 Redundancy – Solutions for I/Os
Flexible Modular Redundancy
Redundancy Evaluation is done in the controller (Code automatically generated during compilation) read both input discrepancy check (AI: tolerance, DI: Change) write both outputs alarming and error handling Usage of selected standard I/O’s for redundancy
I/O Module

Fast and easy field connection with MTA’s
I/O module redundant

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Benefits: wide range of standard and safety I/O modules available for redundancy no difference between redundant and non redundant engineering flexible, user defined redundancy

SIMATIC PCS 7 Redundancy – Solutions for I/Os
Flexible Modular Redundancy

Dual
DO DO DI AI

Make any component redundant Physically separate redundant resources Mix and match redundancy Fieldbus architecture allows system to tolerate multiple faults without interruption I/O redundancy independent of CPU redundancy

Simplex
AI

Triple
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DO

DI

AI

AI

SIMATIC PCS 7 – Redundancy at all levels
Solutions for Communication
WEB Client SIMATIC IT Office LAN (Ethernet) Client Station WEB Server (OPEN PCS 7) OS LAN (Ethernet) OS Server ROUTE Control BATCH Server Industrial Ethernet AS 41x HF ET200M HF ET200S ET200M HF (Standard & F-Modules) ET200M HF ET200iSP CAS Engineering/ Maintenance Station

AS 41x PROFIBUS DP

SIMOCODE

ET200iSP

PROFIBUS PA

PROFIBUS DP

PROFIBUS PA

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SIMATIC PCS 7 Redundancy – Solutions for Communication
Ethernet & PROFIBUS DP
Operator stations

Enhanced availability through optical or electrical ring topologies Ring structures are capable to bridge a broken cable at any location in the ring. Terminal bus and Plant bus: Industrial Ethernet with electrical and/or optical switches (ESM/OSM, SCALANCE)
Profibus DP

Terminal bus

Redundant OS Server

Plant bus

Field bus: PROFIBUS DP with optical link modules (OLM)
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Profibus DP

SIMATIC PCS 7 Redundancy – Solutions for Communication
Ethernet & PROFIBUS DP
Redundant subcomponents e.g. redundant CPs With redundant CPs the system can tolerate the failure of a CP or a switch Redundancy at the Computer level is independent to CP redundancy on the controllers
Profibus DP Operator stations

Terminal bus

Redundant OS Server

Plant bus

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Profibus DP

SIMATIC PCS 7 Redundancy – Solutions for Communication
Ethernet & PROFIBUS DP
Redundancy of all components can handle multiple errors A redundant ring topology can tolerate double failures like switch failure and a broken cable.
Operator stations

Terminal bus

Redundant OS Server

Plant bus

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Profibus

SIMATIC PCS 7 Redundancy – Solutions for Communication
PROFIBUS PA
One reason for the slow adoption of field buses has been the lack of redundancy. The failure of a critical element could have lead to the loss of many devices.
1 Loss of the coupler 2 Short-circuit / wire break on backbone 3 Short-circuit / wire break on spur 4 Missing bus termination
4
Backbone Fieldbus (e.g. PA, FF)

Bus coupler, non redundant

1 2 3
Bus termination

...

max. 31 devices per coupler

spur

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With PROFIBUS PA this is no longer true, as key elements can now be redundant.

SIMATIC PCS 7 Redundancy – Solutions for Communication
PROFIBUS PA Redundancy

Coupler Redundancy
PROFIBUS DP
M

Coupler-Redundancy
DP/PA-coupler, redundant (M = master) AFS

IM 153, redundant

Active Field Splitter PROFIBUS PA

Bus termination Automatic bus termination

PA Ring Redundancy
PROFIBUS DP

Coupler-Redundancy
M M

DP/PA-coupler, redundant (M = Master) AFD

Media redundancy based on a ring topology
AFD Active Field Distributor

IM 153, redundant

PROFIBUS PA page 32 AFD AFD

SIMATIC PCS 7 Redundancy – Solutions for Communication
PROFIBUS PA Redundancy
PROFIBUS DP

M

DP/PA coupler, redundant

AFD IM 153, redundant

PROFIBUS PA

Active field distributor
U1, I1 S1 S3
Bus termination
-

S2

U2,I2

Automatic bus termination in the event of short-circuit or wire break on the main line Up to 8 AFD can be connected per redundant ring

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SIMATIC PCS 7 Redundancy – Solutions for Communication
PROFIBUS PA Redundancy Add new devices Expand line Expand ring

M

PROFIBUS PA

AFD

AFD

AFD

AFD

AFD

Bus termination Automatic bus termination

Mixed operation of single and redundant DP/PA Couplers in one DP/PA Link possible
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SIMATIC PCS 7 Maximum Scalability (1:1000)
Pilot plant Production plant Interconnected plants at a production location

Scalable From a laboratory system (~100 I/O)...

...to the distributed system in client/ server architecture (~ 120.000 I/O)

… as powerful as you need it to be!
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SIMATIC PCS 7 Scalable Redundancy

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… as Redundant as you need it to be!

PCS 7 Application Note: PCS 7 Architectures
http://support.automation.siemens.com/WW/view/en/28430682
PCS 7 I/O Redundancy Setup and Wiring (incl. MTA) Configuring Redundant I/O Function Diagnostics

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PCS 7 Application Note: PCS 7 Architectures
Standard PCS 7 Architectures Box Systems Single Station Client-Server Redundancy Options Batch/Route Control PDM, Asset Management, Safety Visio Drawings including Operator Stations Networks (Ethernet, Profibus) Controllers Bill of Materials Part No.

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PCS 7 Application Note: PCS 7 Architectures Examples

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SIMATIC PCS 7
Takes you beyond the limits!

Questions ?

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