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Automation and Drives

Redundancy and fault tolerance with PCS 7


SIMATIC PCS 7 V6.1 + SP1
Redundancy and
Topics
fault tolerance
with PCS 7

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 1


Automation and Drives

Redundancy and fault tolerance with PCS 7


Introduction and Overview

¾ Process control systems are responsible for controlling,


Topics monitoring and documenting production and manufacturing

processes.
¾ The increasing degree of automation and the demand that
these systems be cost-effective mean that the availability of
the systems implemented is playing an increasingly significant
role.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 2


Automation and Drives

Redundancy and fault tolerance with PCS 7


Introduction and Overview

¾ Failure of the control system or individual components of the


Topics control system can lead to costly production standstills.

¾ In the case of processes in process engineering you must


consider not only the loss of production caused by the
standstill, but also the costly restarting of a continuous
process.
¾ Furthermore, there is the risk of losing a whole batch
due to lack of quality assurance data.
¾ In addition, if process operation without supervision or
maintenance personnel is required, then the process system
must be configured to be redundant across the board
including all the associated components.
SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 3
Automation and Drives

Redundancy and fault tolerance with PCS 7


Introduction and Overview

¾ The availability is heightened by doubling-up all the key


Topics components of PCS 7 and ensuring support through relevant

software mechanisms.
¾ The components of SIMATIC PCS 7 can be classified as
Field level, Process level and Control level components.
¾ SIMATIC PCS 7 provides a solution for each component
of a specific level.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 4


Automation and Drives

Redundancy and fault tolerance with PCS 7


Definition of availability and fault tolerance

¾ A system is designated as being available when it is able to


Topics fulfill the tasks for which it is intended.

Availability is designated as the probability that a system


is functional (available) within a specified period of time.
¾ A system is considered to be fault tolerance when an
application even in the case of failure continues to be
available and can continue to be used without immediate
human intervention.
Fault tolerance therefore designates the ability of a
system to ensure unrestricted operation if one of
its components fails.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 5


Automation and Drives

Redundancy and fault tolerance with PCS 7


Definition redundancy

¾ In technology, the term "redundancy" generally designates


Topics the additional presence of functionally identical or

comparable resources of a technical system when they


are not required in a normal case of trouble-free operation.
¾ The functional redundancy described here has the purpose
of having multiple configurations of safety systems in so
that if a component fails, the others ensure continued service.
In addition, it is attempted to separate the redundant systems
physically from each other. This minimizes the risk of the
systems being subject to the same failure at the same time.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 6


Automation and Drives

Redundancy and fault tolerance with PCS 7


Basic configuration
Operator stations

Topics
OS LAN Ethernet

Engineering Station ES PC with OS Server


SIMATIC PDM integrated Batch-Server Central Archive Server (CAS)
RAID 1 RC-Server

Industrial Ethernet / Fast Ethernet

ET 200M ET 200M ET 200M ET 200M ET 200M

PROFIBUS PA

MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 7


Automation and Drives

Redundancy and fault tolerance with PCS 7


Terminal and process bus ring
Operator stations

Terminal bus
Topics ring
OS LAN Ethernet

Engineering Station ES OS Server


SIMATIC PDM Batch-Server Central Archive Server (CAS)
Process bus RC-Server
ring

Industrial Ethernet / Fast Ethernet

ET 200M ET 200M ET 200M ET 200M ET 200M

PROFIBUS PA

MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 8


Automation and Drives

Redundancy and fault tolerance with PCS 7


Redundant OS servers
Operator stations

Topics
Redundant
OS LAN Ethernet
servers
Engineering Station ES OS Server
SIMATIC PDM Batch-Server Central Archive Server (CAS)
RC-Server

Industrial Ethernet / Fast Ethernet

ET 200M ET 200M ET 200M ET 200M ET 200M

PROFIBUS PA

MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 9


Automation and Drives

Redundancy and fault tolerance with PCS 7


Redundant connection of sensors
Operator stations

Topics
OS LAN Ethernet

Engineering Station ES OS Server


SIMATIC PDM Batch-Server Central Archive Server (CAS)
RC-Server

Industrial Ethernet / Fast Ethernet

Redundant Redundant
connected sensors
sensor
ET 200M ET 200M ET 200M ET 200M ET 200M
Sensoren
Sensor
PROFIBUS PA

MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 10


Automation and Drives

Redundancy and fault tolerance with PCS 7


PROFIBUS ring
Operator stations

Topics
OS LAN Ethernet

Engineering Station ES OS Server


SIMATIC PDM Batch-Server Central Archive Server (CAS)
RC-Server

Industrial Ethernet / Fast Ethernet

PROFIBUS ring

ET 200M ET 200M ET 200M ET 200M ET 200M

PROFIBUS PA

MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 11


Automation and Drives

Redundancy and fault tolerance with PCS 7


Implementation of fault tolerance S7-400Hs
Operator stations

Topics
OS LAN Ethernet

Engineering Station ES OS Server


SIMATIC PDM Batch-Server Central Archive Server (CAS)
RC-Server

Industrial Ethernet / Fast Ethernet

Redundant
Redundant controllers
PROFIBUS ET 200M ET 200M ET 200M ET 200M ET 200M

Y Link

MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 12


Automation and Drives

Redundancy and fault tolerance with PCS 7


Double PROFIBUS ring
Operator stations

Topics
OS LAN Ethernet

Engineering Station ES OS Server


SIMATIC PDM Batch-Server Central Archive Server (CAS)
RC-Server

Industrial Ethernet / Fast Ethernet

Redundant
PROFIBUS rings
ET 200M ET 200M ET 200M ET 200M ET 200M

PROFIBUS
PA
MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 13


Automation and Drives

Redundancy and fault tolerance with PCS 7


Process bus configured as double ring
Operator stations

Topics
OS LAN Ethernet

Engineering Station ES OS Server


SIMATIC PDM Batch-Server Central Archive Server (CAS)
RC-Server

Redundant
Industrial Ethernet / Fast Ethernet
process bus rings

ET 200M ET 200M ET 200M ET 200M ET 200M

Y Link PROFIBUS
PA
MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 14


Automation and Drives

Redundancy and fault tolerance with PCS 7


4-way redundancy on the process bus
Operator stations

Topics
OS LAN Ethernet

2 redundant ES OS Server
interfaces per Batch-Server Archive Server (CAS)
controller RC-Server

Industrial Ethernet / Fast Ethernet

ET 200M ET 200M ET 200M ET 200M ET 200M

Y Link PROFIBUS
PA
MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 15


Automation and Drives

Redundancy and fault tolerance with PCS 7


Double ring on the terminal bus
Operator stations

Redundant
network cards
Topics
Redundant
OS-LAN Ethernet
terminal bus rings

Engineering Station ES OS Server


SIMATIC PDM Batch-Server Zentraler Archiv Server (CAS)
RC-Server

Industrial Ethernet / Fast Ethernet

ET 200M ET 200M ET 200M ET 200M ET 200M

Y Link PROFIBUS
PA
MCC MCC MCC MCC MCC

ET 200iSP ET 200iSP ET 200iSP ET 200iSP ET 200iSP

Zone 1
Zone 2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 16


Automation and Drives

Redundancy and fault tolerance with PCS 7


Basic configuration

¾ The server and single stations from the PCS 7 catalog


Topics are delivered by default with RAID 1 (mirror disks).

¾ Optionally, high-performance servers are also available


as add-ons for PCS 7. They will be delivered with
RAID-systems.
Furthermore a lot of components can be selected as
redundant:
- Power supply unit
- hotplug hard disks
- ...

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 17


Automation and Drives

Redundancy and fault tolerance with PCS 7


Terminal and process bus ring

¾ Building rings is the simplest form increasing the


Topics availability. Using a ring structure the communication

will not be affected by a fault.


¾ Precondition is the usage of SIMATIC NET switches,
where the functionality „Redundancy manager“ is
implemented.
¾ The bus is automatically reconfigured within a maximum
of 0.3s.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 18


Automation and Drives

Redundancy and fault tolerance with PCS 7


Implementation of redundant servers

¾ Implementation of redundant servers greatly increases


Topics system availability.

¾ It is possible to completely load the servers without


loss of operability.
¾ The process values are captured continuously by both
servers (hot stand-by).
¾ If one of the two servers fails, the archives are matched
automatically.
¾ For increasing of performance the clients are divided
between the two servers.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 19


Automation and Drives

Redundancy and fault tolerance with PCS 7


Redundant connection of sensors

¾ 2 I/O modules for capturing process values.


Topics
¾ Module change without loss of process values.
¾ Partial external switching with diodes required.
¾ Not all modules are approved for redundant
implementation.
¾ The breakdown of a module does not affect the plant.
The signal is still available from the single implemented
sensor.
¾ Using 2 redundant sensors will increase the availability.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 20


Automation and Drives

Redundancy and fault tolerance with PCS 7


Ring redundancy on the PROFIBUS DP

¾ Building rings is the simplest form of increasing


Topics the availability. Using a ring structure the

communication will not be affected by a single fault on


the bus.
¾Configuration possible only with OLM Æ
optical PROFIBUS ring

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 21


Automation and Drives

Redundancy and fault tolerance with PCS 7


Implementation of fault tolerance S7-400Hs

¾ Two S7-400s in the hot stand-by system.


Topics
¾ Continuous matching of the process values and
the program.
¾ Rapid switchover in case of failure.
¾ Hardware changes can be loaded without
CPU stop.
¾ Redundant connection of the ET 200 family.
¾ Via Y Link it is possible to connect PROFIBUS devices
with just one PROFIBUS connection.
Page 1/2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 22


Automation and Drives

Redundancy and fault tolerance with PCS 7


Implementation of fault tolerance S7-400Hs

¾ By using two IM 153-2 interface modules


Topics in a distributed I/O device you can configure

switched distributed I/Os.


¾ For redundant operation two interface modules
are mounted on the bus module in the distributed
I/O device.
¾ If the active interface module fails, the passive
interface module takes over the relevant functions
in a bumpless transfer.
Page 2/2

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 23


Automation and Drives

Redundancy and fault tolerance with PCS 7


Double PROFIBUS ring

¾ Building rings is the simplest form of increasing


Topics the availability. Using a ring structure the

communication will not be affected by a single fault on


the bus.
¾ Configuration possible only with OLM Æ
optical PROFIBUS ring

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 24


Automation and Drives

Redundancy and fault tolerance with PCS 7


Double ring as process bus

¾ In this system, one CP 1613 can fail per OS server


Topics or per AS one CPU or one CP 443-1 per automation

system without affecting the functionality of the plant.


¾ The system bus is twofold and configured as redundant
with OSM in each case. This then also covers failure
of the BUS component including all the components
involved (OSM/ESM).
¾ The configuration is only possible with H systems.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 25


Automation and Drives

Redundancy and fault tolerance with PCS 7


4-way redundancy on the process bus

¾ In this system, one CP 1613 can fail per OS server


Topics or per AS one CPU or one CP 443-1 per subsystem of

the automation system without affecting the


functionality of the plant.
¾The configuration is only possible with H systems.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 26


Automation and Drives

Redundancy and fault tolerance with PCS 7


Double ring on terminal bus

¾ It is released from Version PCS 7 V6.1 + SP1


Topics
¾ The usage of special network cards, supporting
„Teaming“ of network cards, is necessary.
¾ Following the concept, both rings have to be connected
to each other.
¾ Futhermore the same advantages are valid like with
the redundant ring on the process bus.

SIMATIC PCS 7 V6.1 + SP1 Siemens AG Slide 27