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Automation and Drives

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

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

Redundancy and fault tolerancewith PCS 7


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Redundancy and fault tolerance with PCS 7Introduction and Overview

Process control systems are responsible for controlling,monitoring and documenting production and manufacturingprocesses.

The increasing degree of automation and the demand thatthese systems be cost-effective mean that the availability ofthe systems implemented is playing an increasingly significantrole.


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Failure of the control system or individual components of thecontrol system can lead to costly production standstills.

In the case of processes in process engineering you mustconsider not only the loss of production caused by thestandstill, but also the costly restarting of a continuousprocess.

Furthermore, there is the risk of losing a whole batchdue to lack of quality assurance data.

In addition, if process operation without supervision ormaintenance personnel is required, then the process systemmust be configured to be redundant across the boardincluding all the associated components.


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The availability is heightened by doubling-up all the keycomponents of PCS 7 and ensuring support through relevantsoftware mechanisms.

The components of SIMATIC PCS 7 can be classified asField level, Process level and Control level components.

SIMATIC PCS 7 provides a solution for each componentof a specific level.


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Redundancy and fault tolerance with PCS 7Definition of availability and fault tolerance

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

A system is considered to be fault tolerance when anapplication 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.


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Redundancy and fault tolerance with PCS 7Definition redundancy

In technology, the term "redundancy" generally designates 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.

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 thesystems being subject to the same failure at the same time.


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Redundancy and fault tolerance with PCS 7Basic configuration

PROFIBUS PA

OS LAN Ethernet

Industrial Ethernet / Fast Ethernet

Operator stations

Zone 2

Zone 1

Engineering Station ESSIMATIC PDM

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

Central Archive Server (CAS)PC withintegratedRAID 1

OS Server Batch-Server RC-Server


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Redundancy and fault tolerance with PCS 7

PROFIBUS PA

OS LAN Ethernet


Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M


Terminal busring

Process busring

Terminal and process bus ringOperator stations

Central Archive Server (CAS)OS Server Batch-Server RC-Server


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OS LAN Ethernet

PROFIBUS PA

Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

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ET 200M

ET 200iSP

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ET 200M



Redundant servers

Redundant OS serversOperator stations

Central Archive Server (CAS)OS Server Batch-Server RC-Server


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SensorenSensor PROFIBUS PA

OS LAN Ethernet

Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

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MCC

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MCC

ET 200M

ET 200iSP

MCC

ET 200MET 200M



Redundant connectedsensor

Redundant connection of sensorsOperator stations


Central Archive Server (CAS)

ET 200M

Redundantsensors


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PROFIBUS PA

OS LAN Ethernet

Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M



PROFIBUS ring

PROFIBUS ringOperator stations




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Y Link

OS LAN Ethernet

Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

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ET 200M

ET 200iSP

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ET 200M



RedundantcontrollersRedundant

PROFIBUS

Implementation of fault tolerance S7-400HsOperator stations




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PROFIBUS PA

OS LAN Ethernet

Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M



RedundantPROFIBUS rings

Double PROFIBUS ringOperator stations




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Y Link

OS LAN Ethernet


Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

PROFIBUS PA


Redundantprocess bus rings

Process bus configured as double ringOperator stations




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OS LAN Ethernet

Archive Server (CAS)

Y Link


Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

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ET 200M

ET 200iSP

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ET 200M

PROFIBUS PA

2 redundant interfaces per controller

ES

4-way redundancy on the process busOperator stations



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Y Link


Zone 2

Zone 1

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

MCC

ET 200M

ET 200iSP

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ET 200M

PROFIBUS PA

Double ring on the terminal busOperator stations

OS-LAN Ethernet

Redundantnetwork cards


Engineering Station ESSIMATIC PDM Zentraler Archiv Server (CAS)

Redundant terminal bus rings


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Redundancy and fault tolerance with PCS 7Basic configuration

The server and single stations from the PCS 7 catalogare delivered by default with RAID 1 (mirror disks).

Optionally, high-performance servers are also availableas add-ons for PCS 7. They will be delivered withRAID-systems.Furthermore a lot of components can be selected asredundant:- Power supply unit- hotplug hard disks- ...


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Redundancy and fault tolerance with PCS 7Terminal and process bus ring

Building rings is the simplest form increasing theavailability. Using a ring structure the communicationwill not be affected by a fault.

Precondition is the usage of SIMATIC NET switches,where the functionality „Redundancy manager“ isimplemented.

The bus is automatically reconfigured within a maximumof 0.3s.


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Redundancy and fault tolerance with PCS 7Implementation of redundant servers

Implementation of redundant servers greatly increasessystem availability.

It is possible to completely load the servers withoutloss of operability.

The process values are captured continuously by bothservers (hot stand-by).

If one of the two servers fails, the archives are matchedautomatically.

For increasing of performance the clients are dividedbetween the two servers.


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Redundancy and fault tolerance with PCS 7Redundant connection of sensors

2 I/O modules for capturing process values.

Module change without loss of process values.

Partial external switching with diodes required.

Not all modules are approved for redundantimplementation.

The breakdown of a module does not affect the plant.The signal is still available from the single implementedsensor.

Using 2 redundant sensors will increase the availability.


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Redundancy and fault tolerance with PCS 7Ring redundancy on the PROFIBUS DP

Building rings is the simplest form of increasingthe availability. Using a ring structure thecommunication will not be affected by a single fault onthe bus.

Configuration possible only with OLM optical PROFIBUS ring


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Redundancy and fault tolerance with PCS 7Implementation of fault tolerance S7-400Hs

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

Continuous matching of the process values andthe program.

Rapid switchover in case of failure.

Hardware changes can be loaded withoutCPU stop.

Redundant connection of the ET 200 family.

Via Y Link it is possible to connect PROFIBUS deviceswith just one PROFIBUS connection.

Page 1/2


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Redundancy and fault tolerance with PCS 7Implementation of fault tolerance S7-400Hs

By using two IM 153-2 interface modulesin a distributed I/O device you can configureswitched distributed I/Os.

For redundant operation two interface modulesare mounted on the bus module in the distributedI/O device.

If the active interface module fails, the passive interface module takes over the relevant functionsin a bumpless transfer.

Page 2/2


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Redundancy and fault tolerance with PCS 7Double PROFIBUS ring

Building rings is the simplest form of increasingthe availability. Using a ring structure thecommunication will not be affected by a single fault onthe bus. Configuration possible only with OLM optical PROFIBUS ring


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Redundancy and fault tolerance with PCS 7Double ring as process bus

In this system, one CP 1613 can fail per OS serveror per AS one CPU or one CP 443-1 per automationsystem without affecting the functionality of the plant.

The system bus is twofold and configured as redundantwith OSM in each case. This then also covers failureof the BUS component including all the componentsinvolved (OSM/ESM).

The configuration is only possible with H systems.


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Redundancy and fault tolerance with PCS 74-way redundancy on the process bus

In this system, one CP 1613 can fail per OS serveror per AS one CPU or one CP 443-1 per subsystem ofthe automation system without affecting thefunctionality of the plant.

The configuration is only possible with H systems.


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Redundancy and fault tolerance with PCS 7Double ring on terminal bus

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

The usage of special network cards, supporting„Teaming“ of network cards, is necessary.

Following the concept, both rings have to be connectedto each other.

Futhermore the same advantages are valid like withthe redundant ring on the process bus.

Date post:	25-Jun-2015
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