High Availability AU PUBLIC INFORMATION. Allen-Bradley. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

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1 High Availability AU PUBLIC INFORMATION Allen-Bradley Rev 5058-CO900E

2 2 Agenda Why High Availability? Why is Availability Important? PlantPAx Controller Redundancy Alarms & Events Server Solution Questions

3 3 Why High Availability? Ensures a certain absolute degree of operational continuity during a given time period. (Mission Period) High availability is more than Redundancy! Availability is the readiness for a system to perform when needed. Availability is measurable Represented as a % Allen-Bradley Commonly known as number of nines

4 4 Agenda Why High Availability? Why is Availability Important? PlantPAx Controller Redundancy Alarms & Events Server Solution Questions

5 5 Why is Availability Important? To protect people, installations & production quota Ensure you maintain your plant running Provide backup systems for key Applications Enable System upgrades while running production Allen-Bradley

6 6 ARC Estimated Losses per Hour Availability Possible Downtime Per Year Estimated Cost Per Year based on $12,500/hour 99% 3.5 days $1,050, % 9 hours $112, % 53 minutes $11, % 5 minutes $1, % 30 seconds $104

7 7 MTTF,MTTR, MTBF MTBF (Mean Time Between Failure) MTTF (Mean Time To Failure) MTTR (Mean Time To Repair) Successful Operation Failure TIME MTBF is a term that applies only to repairable systems. 10 Hours is a common time period used for MTTR calculations Allen-Bradley

8 8 PlantPAx with Integrated Architecture = 1 day every 3 years Availability % Possible Downtime per Year 99% 3.65 days 99.9% 8.76 hours 99.99% 52.6 minutes % 5.26 minutes % 30 seconds Simplex PlantPAx Redundant PlantPAx Availability is measurable as a %: A = MTBF / MTBF+MTTR

9 9 How PlantPAx Increases Availability Maintainability Improved Diagnostics: Internal diagnostics to detect failures and LED indicators Diagnostic I/O modules: Wire off, shorts, etc. Hart and other Fieldbus technology with sensor & actuator diagnostics. Alarms and Events Runtime Modifications: Runtime partial import. Online Edits of user application Hot Swap modules Addition of modules in Run mode Ability to update firmware at Runtime Allen-Bradley Ease of Maintainability Results in Minimized Downtime

10 10 Where are we providing high Availability? Availability Safety

11 Redundancy & Availability is How Much? Economics should drive How Much. Cost of Lost Product Cost of Lost Data Damage to Equipment Cost of Downtime Loss of View Cost of Hazard Common Applications Power Generation, Paper Machines Biotech Batches Reactors Fractional Distillation Replicated OWS Redundant L2 Switch Redundant Server Redundant L2 Switch Redundant L3 Switch (Router) Redundant L2 Stratix Redundant Controller Dual ControlNet Media Limited Fault Tolerant IO Fault Tolerant Termination Block Allen-Bradley Redundant Field Device PS PS PS PS OWS Sw P OWS Sw S PASS PASS Sw P Sw S Sw P Sw S Sw P CLX P Sw S CLX S 1756 I/O 1756 I/O FT-TB TR TR PS PS PS PS PUBLIC INFORMATION Note: Power is supplied by separated sources, and redundant Power supplies are implied 11

12 12 Agenda Why High Availability? Why is Availability Important? PlantPAx Controller Redundancy Alarms & Events Server Solution Questions

13 13 PlantPAx Controller Redundancy Controller Redundancy Dual controller / chassis configuration Failure of a controller or any other chassis component will cause control to transfer to secondary chassis No special programming required Less start up and troubleshooting time Easy to Implement One checkbox Runtime migration of firmware and hardware Also can be used as a Redundant Gateway Allen-Bradley

14 14 Redundancy Features Absolutely no user programming required to implement. Bump less switchover guaranteed for outputs in the highest priority task. Switchover within approximately 20 msec Works with all current standard hardware*. Switchovers are transparent to any devices networked to the redundant controller chassis. Transparent cross-load of programs from primary to secondary controllers only one application to maintain. On-line configuration changes or edits to primary are automatically forwarded to secondary. User can choose to cancel or resume test edits at switchover. * Firmware version required for some older communications modules to function in Redundancy Chassis

15 15 Common Network Backbone What: Introduction of Ethernet/IP I/O in Redundant architectures. Why: Integrates all levels of the system onto one common network Standard Unmodified Ethernet 3 rd party module support Easier integration with ERP systems Allen-Bradley

16 16 High Availability Network Architecture What: DLR Ring topology Why: Fault tolerant network architecture. Able to tolerate any single fault to the media No managed switches required Faster recovery than REP protocol. 3ms VS 70ms Common Maintenance capability

17 Common Network Backbone Example NTP NTP Redundant A&E Servers NTP PTP PTP NTP NTP/PTP Allen-Bradley 17

18 1715 Redundant I/O Fault Tolerant I/O Duplex or Simplex Operation Duplex or Simplex Wiring Termination Bases 24VDC Discrete Input Module 24VDC Discrete Output Module 4 to 20 ma Analog Input Module 4 to 20 ma Analog Output Module 16 Bit AtoD Converter Redundant Ethernet Adapter Redundant Input Modules Redundant Output Modules Redundant 24VDC Power supply connections Ability to operate on DLR Topologies Automatic Switch over in the event of any fault in a module pair. PUBLIC INFORMATION 18

19 High Availability Solution 1) PlantPAx ( L7) 2) E/IP I/O on Redundancy 3) E/IP Ring (DLR) 4) 1715 Redundant I/O 5) A&E Support for redundant HMIs 6) RSLogix 5000 Features Higher performance Common network backbone for redundant architectures High Availability network path High Availability I/O solution. Finalizes High Availability Server solution. Features available in for improved Availability Allen-Bradley

20 20 Agenda Why High Availability? Why is Availability Important? PlantPAx Controller Redundancy Alarms & Events Server Solution Questions

21 21 Alarms & Events Server Solution What Two separate redundancy configurations Device-based alarming Tag-based alarming via tag-based alarm server Auto-synchronization between Primary and Secondary alarm servers Single Alarm History Configuration Primary and Secondary alarm servers, when active, will individually log alarms to the same database. Allen-Bradley

22 For additional information: PlantPAx : O&G information: Download Process Safebook: Request a PlantPax Demo: Join us at PSUG & AF:

23 Allen-Bradley Rev 5058-CO900E

24 Questions? PUBLIC INFORMATION Rev 5058-CO900E