PROCESS AUTOMATION

PROBABILITY AND REDUNDANCY

TECHNICAL WHITE PAPER

P
rocess plants are striving now more than ever to reduce
operational expenditures while increasing productivity and
efficiency. Today’s process engineers place a tremendous
amount of emphasis on system integrity requirements. Why?
Because it’s a variable that can be controlled when the right
equipment is in place.

Kristen Barbour
Product Marketing Manager
Monitoring and Protection
Part No. TDOCT-B004_USA
 TECHNICAL WHITE PAPER

Table of Contents

System Integrity Requirements........................................... 3

Redundancy.......................................................................................... 3
Parallel Redundancy............................................................................ 3
Standby Redundancy........................................................... 3
Redundant Power Supplies................................................. 4
N+1 Power Redundancy....................................................... 4
N+N Power Redundancy....................................................... 5
Redundancy Solutions......................................................... 6
Notes...................................................................................... 7

2
 PROBABILITY AND REDUNDANCY

System Integrity Requirements One or more system components are connected for
redundancy but by default one is the primary in full
System integrity: State of a system where it is operation. The secondary, by default, is not in operation
performing its intended functions without being under normal operating conditions. The switch from
degraded or impaired by changes or disruptions in its primary to secondary source is done to resume normal
internal or external environments. operations.

Process plants are striving now more than ever to Standby Redundancy
reduce operational expenditures while increasing In a standby redundancy configuration additional
productivity and efficiency. Today’s process engineers components are necessary to switch between the
place a tremendous amount of emphasis on system primary and secondary source. See figure 2. This
integrity requirements. Why? Because it’s a variable switching is not seamless and adds to the probability
that can be controlled when the right equipment is in of failure within a given system. To offset this increased
place. probability, additional hardware can be added to the
redundancy configuration to help assist in the switching
System reliability is a calculation based on estimates. from the primary to secondary source. While these
Certain procedures and component evaluations are system components add to the reliability, they are
used to predict the integrity of a given system or normally connected in series, which creates a hybrid
individual component. Each component of a system parallel-series connection and introduces another point
is evaluated individually and its probability of failure of failure for the system.
is estimated. The manner in which components are
connected will influence the integrity of the system. For
example a system component connected in series will
have more probable impact on the system integrity than
a more reliable parallel connection. Each component Figure 2
estimates are combined to provide an over all estimate
to the probability of failure for a given system. Redun-
dancy is used to add to the systems overall availability
and reduce a given systems probability of failure.

Redundancy

Parallel Redundancy
Two or more system components are operating
simultaneously. Only one component is required to
be working for the system to operate, and it should
continue to function at acceptable performance levels
after the loss of any component. Both components
must fail in order for a system failure. See figure 1.

Figure 1

3
 TECHNICAL WHITE PAPER

Redundant Power Supplies With an N+1 redundant configuration, multiple

components (N) have at least one independent backup
Power supply redundancy is a very popular means to component to ensure system functionality continues
increase system reliability. in the event of a system failure. In a power supply
Industrial process facilities rely tremendously on the configuration, N represents the primary power supplies,
bulk power supplies because they not only power and + 1 represents one power supply that is backing up
the control system architecture but also bus powered that primary supplies.
control and measurement instruments. These critical
continuous production process applications require
more than a single off-the-shelf industrial power The PS3500 is Pepperl+Fuchs’ modular N+1
supply. A single power supply failure could have a power supply. It provides economical reliability and
catastrophic effect that equates to a tremendous redundancy to a power system. The balanced load
amount of lost revenue. This need for system integrity sharing of the PS3500 enables all of the modules to
and guaranteed performance in these demanding share the load evenly. This load sharing functionality
conditions necessitates power redundancy. N+1 is an is built-in to each power supply, without the need
affordable redundancy method that guarantees system for an external diode module. Balanced load share
functionality will continue even during a supply failure. ensures that one power module is not working harder
than another, adding to the longevity of the power
supply modules. The PS3500 power supply is easily
N+1 Power Redundancy expandable in 15 A increments just by adding another
module when the load requirement increases. The end
In the simplest terms, N+1 is a robust power supply result is a highly available and affordable redundant
redundancy method that guarantees continuous power solution.
system functionality in the event of a single power
supply failure. With redundancy‚ a supply failure will
not initiate an emergency repair situation; it can be
replaced without shutting down the power system or
the process. See figure 3.

Figure 3
An N+1 redundant configuration

4
 PROBABILITY AND REDUNDANCY

N+N Power Redundancy N+N is commonly used for noncritical systems. In

practice, N+N is used for loads smaller than 40 A. It
An N+N redundant topology consists of two power may be difficult to increase the load and even more
supplies of equal power coupled by a diode that work difficult to expand your existing system. In an instance
together to power the same load. N+N redundancy where you have an N+N system where N = 20 A, you
is an economical solution when a redundant power would have to replace both 20 A modules if the load
system is required; however this is not recommended requirement became 30 A or 40 A.
for critical processes.

In an N+N configuration a diode module is required

to connect the two power supplies. The use of diode
modules will causes an unbalanced load on one of
the power supplies requiring certain modules to work
harder than others, resulting in premature aging of
the power module. This failure results in increased
maintenance and operating expenditures. In N+N
configurations hot swapping in normally not permitted
while in operation. See figure 4.

Figure 4
An N+N configuration

5
 TECHNICAL WHITE PAPER

Redundancy Solutions • Lower cost doesn’t always equal lower total cost of
ownership.
When considering power redundancy solutions: • The cost of one unplanned shutdown far outweighs
the costs of redundancy.
• A typical field marshalling control cabinet ( 2000 X • Buying the right tool for the job…continuous
800 X 800 ) has an average power requirement of process application require continuous duty power
75 A. Every square inch of a marshalling cabinet supplies.
exploited is to maximize the investment. Footprint • Power module efficiency and heat dissipation
and required spacing will have an impact on the • Maintenance associated with internal fans
amount of control network equipment.

6
PROBABILITY AND REDUNDANCY

Notes

7
 TECHNICAL
proCess WHITE PAPER
automation –
protecting your process

For over a half century, Pepperl+Fuchs has provided new concepts for the world of process automation. Our company
sets standards in quality and innovative technology. We develop, produce and distribute electronic interface modules,
Human-Machine Interfaces and hazardous location protection equipment on a global scale, meeting the most demanding
needs of industry. Resulting from our world-wide presence and our high flexibility in production and customer service,
we are able to offer complete individual solutions – wherever and whenever you need us. We are the recognized experts in our
technologies – Pepperl+Fuchs has earned a strong reputation by supplying the world’s largest process industry companies
with the broadest line of proven components for a diverse range of applications.

6
1
3
5
7

1 Worldwide/German Headquarters
2
Pepperl+Fuchs GmbH
Mannheim · Germany
Tel. +49 621 776 2222
E-Mail: pa-info@de.pepperl-fuchs.com
8
2 Asia Pacific Headquarters
Pepperl+Fuchs PTE Ltd.
Singapore
Company Registration No. 199003130E
Tel. +65 6779 9091
E-Mail: pa-info@sg.pepperl-fuchs.com
3 Central/Western Europe &
Africa Headquarters 6 Northern Europe Headquarters
Pepperl+Fuchs N.V. Pepperl+Fuchs GB Ltd.
Schoten/Antwerp · Belgium Oldham · England
Tel. +32 3 6442500 Tel. +44 161 6336431
E-Mail: pa-info@be.pepperl-fuchs.com E-Mail: pa-info@gb.pepperl-fuchs.com
4 Middle East Headquarters 7 Southern/Eastern Europe Headquarters
Pepperl+Fuchs M.E (FZE) Pepperl+Fuchs Elcon srl
Dubai · UAE Sulbiate · Italy
Tel. +971 4 883 8378 Tel. +39 039 62921
E-Mail: pa-info@ae.pepperl-fuchs.com E-Mail: pa-info@it.pepperl-fuchs.com
5 North/Central America Headquarters 8 Southern America Headquarters
Pepperl+Fuchs Inc. Pepperl+Fuchs Ltda.
Twinsburg · Ohio · USA São Bernado do Campo · SP · Brazil
Tel. +1 330 486 0002 Tel. +55 11 4341 8448
E-Mail: pa-info@us.pepperl-fuchs.com E-Mail: pa-info@br.pepperl-fuchs.com

www.pepperl-fuchs.com
8
Subject to modifications • © 2009 PEPPERL+FUCHS, INC. • Part No. TDOCT-B004 _ USA