Professional Documents
Culture Documents
AV AILABILITY, RELIABILITY OR
REDUNDANCY ... RELIEVING THE
CONFUSION
K. M. Renner
Illd ustria l S),stems Group ,'vtarketi,lg. Measurex CO/poratio n. One Results Way.
Cupertillo. CA 950[.1. ['SA
173
174 K. M. Renner
o UI1sd1eduled plant shutdams due to a which will prCl\l'ide the basis for the
ccntrol system failure shcW.d be limited to availability analysis.
00 IIDre than two per year.
o A plant shut.c:bm is defined as loss of feed
to the plant am product to storage, with HARDolARE ANALYSIS
associated trips of eq.dpnent recpi.rirq
greater than two hrurs to retw:n to steady '!he true a;ntrol system hardware reliability
state cperaticn. analysis :lS based upcn the statistical
o No sirqle ccntrol system failure shcW.d fun1amentals whereby the probability of a
prevent the cperatirq persamel fran CXlI1troI system cperatirq withrut failure, for
aooessirq am evaluatirq plant cperaticnal a specified period of time, is defined as it's
status. "reliability." Or more succinctly,
o Any ccntrol system failure affectirq plant "reliability is the probability of survival".
cperaticn shcW.d be able to be analyzed am
remedied within two hrurs. 'Ihree CCI1Cepts help to relate reliability am
o 0.1rrent am historical plant data shcW.d failure:
rot be lost upcn any ccntrol system
failure. o '!he probability of a given system failure
o '!he CCI1Cept of dooble jec:pardy shcW.d be OCOlZTirq is a OCI\i)inaticn of the
ClCI1Sidered in the failure analysis where individual lIXldule or a::JIt)CXleI1t failure
persamel or envircnnental safety is at probabilities.
risk. o '!he failure rate (rn.mi:Jer of failures per
unit time) typically follows the ''bathtub
SUch a failure definiticn set will allow curve." Le. three distinct failure zcnes
detenn:inaticn of the failure !IDdes to be used exist ~ a product's life which are
in a ccntrol system availability analysis. distirgui.shed by failure frequen:y - the
Note that it is :inportant to document infant IIDrtality zcne, ClCI1Stant zcne, and
qualifyirq assunptic:ns that are made in the wear-o.rt: zcne.
derivirq the definiticn set. By looJtirg at a o A micrc:prooessor based JOOdule, or system,
generic control systeu functicnal flow spen:ls the majority of its life in the
architecture (Fig. 1) it is seen that the ClCI1Stant zcne.
serial method by which JOOdule functic:ns are
organized places a reliaJxle cn minimizirq Therefore, the probability of survival,
sirqle points of failure. '!he loss of any (reliability), for a specific period of time,
link or fun1amental element in the CXlI1troI is related to the failure rate by an
hierarchy will adversely affect system up- expcnential expressicn: (ref.4)
time. Any sirqle element that can fail am
precipitate a plant failure, as defined, is R = e ~t (1)
called a "sirqle point of failure." '!he
reliability and predictability of such where: R = reliability
elements will have a marked inpact cn ~ =failure rate (failures/time)
achievirq high availability. t = specific time period.
am as failure rate is the inverse of
mean time between failure (KI'BF):
Few situatic:ns in marufacturirq in::hJstry
require absolutely m sirqle point of failure. MI'BF = 1/~ (2)
An extreme case walld lead to dual final am R = e (-t/MI'BF) (3)
elements, transducers, tezminatic:ns, etc.
l'bile this is possible, sirqle failure points This expressicn exenplifies the limited
may still exist (e.g. switches fran cn-line to pragmatic use of the tenn "reliability".
back-up), am for !IDst applicatic:ns, this is
rot justified. Le. '!he cne year reliability of a system
with a MI'BF of 5 years is 82\.
'!he key issue here is: How do I minimize Inc::reasirq the MI'BF to 10 years gives a
failure risk by increasirq the reliability of reliability of 90%. In fact, to
the weakest links, thereby increasirq Cl\l'erall increase the reliability to 99\, a
system availability? MI'BF of 100 years is required!
To identify which links affect the plant Significantly more practical sense is
cperaticn the prime points to ClCI1Sider accomplished by analyzing the system
include: availability. Le. the total time a system is
in use, and idle rut capable of beirq used .
o What is defined as a failure? Availability and \ uptime are syl'lCI'li'IInl.
o can the plant be partiticned ccntrol-w1se 'Iherefore:
to minimize failure :ilrpact?
o How quickly am cxnveniently can failures Availability System wime
be diagnosed am remeclied? Systeu uptime + Systeu downtime
o What c:pticnal redun:1an::y or bacIoJp ccntrol
system facilities are available shcW.d they or: A= MI'BF
be deemed necessary? MI'BF + MI'lR (4)
o Is lIXldular cn-line replacement possible?
o Are there critical processes or periods where: A = availability
which req.dre enhaooed ccntrol system MI'BF '" the statistical mean time
reliability? between failures (time)
o What level of self d.iagnostics are MI'lR = Mean Time to Repair - time
available cn the ccntrol system? req.rlred to retw:n the system
o can the prooess be ccntrolled JIBIUally in to cperaticn (time).
the event of a ccntrol system failure?
as: MI'BF = 1/~
By addressirq such q.JeStitrlS fran hardware,
software and cperaticnal perspectives, a ilIplies: A = 1/[1 + ~ x MI'lR] (5)
realistic failure definiticn is OClIPleted,
.'h ailabilit\ . Reliability or Redu n danC\" 175
fUn:Jamental analysis, however, the nature of warm) shcW.d be recognized. Any redundant
software and the tools available, determine carp::I'leJlt shoold be pericxlically mc.ni.tored for
that arrt analysis is largely subjective. health while in backup 1OOde. In practice,
Practical ilrprovements to software reliability most redundant systems are subject to CXIIIID'l
are limite:i to the ecan::mic and organizaticnal. IOOde failures which limit the potential
effort recpired to create and enforce detailed availabili ty. such failures are not
deYel.q:ment, t.esti.n;J and qJeratial standards. necessarily hardware faults, but can be
'!he susoeptibility of the OCI'ltrol system due relate:i to qJeratirq ernrircrrnent, software
to software failure is best evaluate:i al this prci>lems or maintenance procedures.
basis.
By relievi1q the oc:nfusial associate:i with the
terms availability, reliability, and
redundan:::y and stressirq the need for thorc:u:Jh
failure definitial, the fc:mrlatial exists for
Develq:ment of a process OCI'ltrol system joint userjven:Jor develq:ment of process
specificatial by the iroustrial user is often OCl'ltrol system architectures to meet specific
anticipate:i with fear. By urrlerstand.irg the plant requirements for SE!alrity, integrity and
key qJeraticnal. factors associate:i with a safety .
OCI'ltrol system for his plant, Il'l.Idl. of the
cq:prehensial can be eliminate:i. In this
respect, control system availability
requirements must be defined with an
cq:preciatial of the relative iIIpacts of
reliabili ty (both hardware and software) and 1. ~ity Ccrttrol Harrlbook. (1951). '!he
maintainability • Abilities. M:&raw--Hill.
2. Renner, KeYyn M. (1985). Develq:ment of an
Prior to arrt analysis of availability, a Autanatial Plan for a Rlannaoeutical
failure definitial DIJSt be resolved anr:rgst Manlfacturirq Plant. Hlarmaoeutical
plant eI'X1ineerirq and qJeratirq persamel . Tgfulology .
nlls definitial fonns the basis for evaluatirq 3. Renner, KeYyn M. (1987). Management
the OCI'ltrol system architecture for ~imJm strategy . for ~lannirq Plant Autanatial.
process uptime. (Figure 5). Food Ernl1lgeI'llP·
4. Hamilton, Paul R. (1987) . Reliability,
'!he ad:litial of redundant ~ is a Availability, and Fault Tolerance.
CXIIIID'l cq:proach taken to enhancirq OCl'ltrol ~.
system availability. While generally 5 . Department of Defense Militazy Harrlbook,
SllCXlE!SSful, careful evaluatial of econcmic and 2170. (1982). Reliability Prediction of
qJeraticnal. justificatial shoold precede such Electrcru.c Equiprent.
a decisial. LimitatialS which can often 6. Jones, T. capers. (1986). Progran1tIirg
detract fran backup systems (both hot and Productivity. l'tGraw--Hill.
M::xlule ~
~U 24.0
576 x 10-6 576 x 10-6
~*2 24.0
CcmnL.i.nk 0.25
0.25 6.25 x 10-8
CcrttrolU 116.2
116.2 1.51 x 10-2
Operator
~ce
-- tIona Network
~viaory
PrOC888Ol'
RegUatory
Procesaor
VO
Termlnatlone
VP Converter.
Tranerrittera
FIl8I Control
EJementa
Oper&to.. Operato..
Coneole 11 Coneole 12
o • I I -0
I I
Control Control
Koclule 12
.
Koclule 11
•n
• ,• ,•
a j~ j~
n 1r 1r ,
"etd I/O "etd I/o
Operato.. Operato..
CoDeole 11 Coneole 12
Control Control
Koclule 11 Koclule 12