w05 – high availability for today’s process market · compactlogix® hot backup update tool was...

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

W05 – High Availability for Today’s Process Market Jeff Ipser – Product Manager

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Agenda

I/O

Networks

Controllers

High Availability Overview


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What it is High Availability

High availability is a system implementation that ensures a certain absolute degree of operational continuity during a given time period. (Mission Period)

Availability is the readiness for a system to perform when needed. Availability refers to the ability of the user community to access the system, whether to submit new work,

update or alter existing work, or collect the results of previous work. In a control system environment, availability also means the control system is performing it’s designed function while doing any of the above things.

High availability techniques are used to... 1. Modify a running system – Reduce planned outages 2. Prevent unplanned outages

Availability is measurable Represented as a % Commonly known as “number of nines”

High availability is more than Redundancy!


High Level Availability in a ControlLogix®® System

Availability % Possible Downtime per Year

99% 3.65 days

99.9% 8.76 hours

99.99% 52.6 minutes

99.999% 5.26 minutes

99.9999% 30 seconds

Standard ControlLogix®

Redundant CLX

Availability is measurable as a %: A = MTBF / MTBF+MTTR


How CLX increases Availability

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 Inherent Machine Diagnostics

Runtime Modifications: Runtime partial import. Online Edits RIUP of 1756, 1715 and 1794/1797 modules Addition of 1756 and 1715 modules in Run mode ControlLogix® Redundancy adds the ability to update

firmware at Runtime

• Maintainability

Ease of Maintainability Results in Minimized Downtime


The HA System – Put Availability where you need it most

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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 Baggage Handling


Agenda

I/O

Networks

Controllers



ControlLogix®® Redundancy

Dual Chassis Design Full Redundancy Both Chassis match

Transparent Primary/Secondary Chassis IP Address Swap ControlNet Node Swap

Easy to use No special code Automatic Crossload Treat as one chassis Uses Standard 1756 hardware

Up To: 2 Controllers 7 Communications Modules


CLX Redundancy Overview

Operation Basics Application from Primary is

automatically loaded into the Secondary processor

Data changes are sent to secondary at the end of each program.

The Secondary controller is Synchronized with the Primary via “Sync Points” at each crossload point.

System is “Floating Master” type. Each chassis is capable of being Primary

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Secondary Chassis

Primary Chassis

1756-RM2


CLX Redundancy Overview Enable Redundancy

Controller Properties

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• New Controller Dialog


CLX Redundancy Considerations

What can’t I do with a CLX Redundancy System Put the following modules in a Redundancy Chassis

I/O DH/RIO DNB Most Third party modules

Motion Control – Sercos or CIP Motion Inhibit a Task Event Task Unicast Data – Redundancy System can be Producer to another

controller as Unicast. Firmware Supervisor

Anything that makes use of a storage card will be stored on two controllers in the event of a switchover.

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CLX Redundancy Conclusion

Easy to use Single program to maintain Data is automatically Crossloaded Single Checkbox to enable Redundancy Uses standard CLX hardware

Transparent IP address and MAC address follows

Primary Most devices on network are unaware

of a switchover Chassis switchover in 20ms range on

average

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Secondary Chassis

Primary Chassis

1756-RM2


CompactLogix®® Hot Backup


CompactLogix® Hot Backup

Features Uses standard hardware and

firmware No added hardware cost Fast Scan time Very flexible Automatic configuration tool CompactLogix® or

ControlLogix® ControlNet or Ethernet I/O

V20 forward will only support Ethernet I/O

250 ms to a few seconds switchover time Application code dependent

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Hot Backup Code Generator Tool

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1

2

3

4 5 6


CompactLogix® Hot Backup Update

Tool was updated in Logix V20

New Features Windows 7 support Event Log Switching code contained in an AOI

New CompactLogix® Controllers Supported 1769-L30ER 1769-L33ER

Available through RA Sales. No cost for the tool but sales must qualify the application.

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AADvance for Process Safety


Fully Scalable AADvance High Availability System 1oo1, 1oo2, 2oo3

SIL 1, 2 or 3.

Transparent

Simplex to TMR


Sil3 Process Safety

Fully Scalable from Single to Triple (TMR) Transparent to the user and System Highest Availability: 3-2-0 Fault Tolerance Hot swap modularity IEC 61131-3 programming Safety certified communications Single to Triple I/O

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Agenda

I/O

Networks

Controllers



Control Network Resiliency

Ethernet/IP Many different Resiliency options Open Technology Ring or Star or Linear

ControlNet Redundant Media Option


Resiliency Protocols and Redundant Topologies Layer 2

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Redundant Star Ring Linear

Cabling Requirements Ease of Configuration Implementation Costs Bandwidth Redundancy and Convergence Disruption During Network Upgrade Readiness for Network Convergence Overall in Network TCO and Performance Best OK Worst

Redundant Star Flex Links

Ring Resilient Ethernet Protocol (REP)

Star/Bus Linear

HMI

Cisco Catalyst 2955

Cell/Area Zone

Cisco Catalyst 3750 StackWise Switch Stack

Controllers, Drives, and Distributed I/O

HMI

Cell/Area Zone

Controllers

Controllers, Drives, and Distributed I/O Cell/Area Zone

Controllers, Drives, and Distributed I/O

HMI

Controllers

Cell/Area Zone

HMI

Controller




Resiliency Protocol

Mixed Vendor Ring Redundant

Star Network

Convergence > 250 ms

Network Convergence 60 - 100 ms

Network Convergence

1 - 3 ms Layer 3 Layer 2

STP (802.1D) X X X X

RSTP (802.1w) X X X X X

MSTP (802.1s) X X X X X

rPVST+ X X X X

REP X X X EtherChannel (LACP 802.3ad) X X X X

Flex Links X X X DLR (IEC & ODVA) X X X X

StackWise X X X X X

HSRP X X X X

GLBP X X X X

VRRP (IETF RFC 3768) X X X X X

Network Resiliency Protocols Selection is Application Driven

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High Availability Network Architecture

• Provides resiliency at the device level through dual port devices.

• Ideal applications include: • Where there are Low cost and ease of

use resiliency requirements • Migration from field bus networks • CIP Sync applications • Where users do not want to use central

switches • Can recover in as fast as 3 ms for a 50 node

ring worst case • Lower cost to implement than other resilient

network types

Device-Level Ring

• Single fault tolerant network provides resiliency

• Device level ring requires no additional hardware to implement


Resiliency Protocols and Redundant Topologies Representative Example

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VFD Drive

HMI

Stratix 8000/8300 REP/MSTP

Class 3 Only

Catalyst 3750 StackWise Switch Stack

Camera

Safety Controller

Servo Drive

I/O Safety I/O VLAN 43

Camera VLAN 43

Controller VFD Drive

HMI

HMI

I/O

Controller

I/O

I/O

I/O

VLAN 103

VLAN 103

Production - VLANs IP Camera - VLAN

Layer 2 Access Link

Layer 2 Interswitch Link/802.1Q Trunk

VLAN 104

Controller

I/O

Levels 0–2 Cell/Area Zones

Industrial Zone Level 3

Any Commercial Protocol is acceptable as long as it meets the application requirements


Characterized Network Architecture

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Server A Server B FA0/1

FA0/3

G0/1

FA0/3 FA0/2 FA0/2 FA0/1

G2/0/25 G2/0/28

G1/0/28

G2/0/26

G1/0/26 G1/0/25 G1/0/27

G0/2

G2/0/27

Client

NIC teaming on servers and client

Cisco 3750

192.168.11.1 192.168.20.1 192.168.110.1

VLANs 100, Native 110, Switch mgmt 10, I/O 11, Zone 20, HMI

Cisco 2960_A 192.168.110.12

Cisco 2960_B 192.168.110.13 G0/1 G0/2

Redundant Logix Controllers

EtherNet/IP DLR

EtherNet/IP

FA1/1 FA1/1

G1/1 G1/2 G1/1 G1/2

Point I/O & ETAP

CLGX B

192.168.10.10 192.168.10.11

192.168.11.12 192.168.11.13

192.168.10.13 – 192.168.10.29

Stratix 8000, B 192.168.110.11 CIP, 192.168.11.9

CLGX A

Stratix 8000, A 192.168.110.10 CIP, 192.168.11.8

StackWise Switch Stack

Cell/Area Zone Levels 0-2


Additional Material Rockwell Automation

Networks Website: http://www.ab.com/networks/

EtherNet/IP Website: http://www.ab.com/networks/ethernet/

Embedded Website: http://www.ab.com/networks/switches/embedded.html

Embedded Switch Technology Manual http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/enet-ap005_-en-p.pdf

Knowledgebase Website: www.rockwellautomation.com/knowledgebase/?OpenForm

Publications: ENET-UM001G-EN-P provides connection and packet rate specs for modules

http://www.ab.com/networks/

http://www.ab.com/networks/ethernet/

http://www.ab.com/networks/switches/embedded.html

http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/enet-ap005_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/ap/enet-ap005_-en-p.pdf

http://www.rockwellautomation.com/knowledgebase/?OpenForm

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/enet-um001_-en-p.pdf


Agenda

I/O

Networks

Controllers



Currently: 24VDC Digital Input 24VDC Digital Output 4-20mA Analog Input 4-20mA Analog Output Ethernet/IP Adapter

Redundant or Simplex Configurations RIUP and Add Online at Runtime Fully Transparent to the user Uses RSLogix 5000 Profiles 24 I/O modules Max

12 pairs or 24 Simplex Automatic Field Wiring Diagnostics

Short, Open SIL 2 Certification January 2013

1715 Redundant I/O

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Redundant 24VDC Power Supply Connectors

Module Pair


1715 Assemblies

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Module

Termination Assembly Base


1715 Transparency

Modules Configure from RSLogix 5000

Modules appear as single modules for ease of use but are

fully redundant


System Review

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Controllers

Networks

I/O


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w05 – high availability for today’s process market · compactlogix® hot backup update tool was...

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