High controller availability in essential applications
August 2004
PLCs, DCSs & Controllers
The new PACSystems high availability solutions provide a scaleable synchronised hot-standby redundant control platform, with transparent process switchover and easy configuration to ensure uptime in essential applications. They are designed to meet the demands of applications requiring seamless operation and zero downtime - where mere moments of interruption can significantly delay operational flow, create excessive operational costs, or pose a threat to product quality.
The PACSystems RX7i offers four times the speed of existing PLC backplanes
This is according to Daniel Coetzee, business manager Sub-Saharan Africa for GE Fanuc Automation. "Developed with GE Fanuc's patented, innovative technology, PACSystems High Availability assures not only maximum uptime but also transparent process switchover," Coetzee maintains. "This fast switchover has measured up to five times faster than other systems with large data transfers in time critical applications, helping users to realise up to 20% more production capacity.
PACSystems High Availability solutions provide synchronised redundancy for any module in a control chain capable of bringing operations to a halt. Should any part of a controller fail, its backup counterpart automatically assumes control."
Its high availability makes the system suitable for a variety of applications in the areas of:
* Offshore, ships, buoys, windmills, pipeline, oil-well auxiliary control, remote pumping stations, field access control and sub-sea applications - where repair costs are very high due to the application's remote access.
* Crane controls, transport systems, fence control, bridge controls, airway lighting, turbine auxiliary, HVAC or water treatment systems - where downtime causes delay in the operational flow.
* Metals mills, cement mixing, oven control or semiconductor manufacturing - where downtime causes increased material waste and/or damaged equipment.
"GE Fanuc combines the most advanced technologies to offer an industry-leading seamless redundant control switchover. There is virtually no overhead added to the control application, making switchover fast and transparent," says Coetzee. The control process and HMI/scada applications never see a 'bump' during a process switchover operation. This functionality maximises data capture, minimises system restarts and protects equipment, assuring maximum process productivity. Configuration is made easier through GE Fanuc's universal programming environment (Proficy Logic Developer) and its redundancy wizard.
Users can set up shared data and I/O for both systems in the redundant configuration in a matter of minutes. Application scalability and modifications are made easy, and the programmer modifies only the application code. The redundancy and data synchronisation are automatically ensured. With multiple and scaleable ways to provide redundancy, a simple implementation can save up to 50% in control hardware cost versus traditional installations.
A typical solution consists of two physically independent controllers connected to a variety of I/O, utilising a proven industrial network that provides deterministic data and automatic switchover.
The controllers incorporate dedicated and redundant links to one another and operate synchronously, transferring all of the application's variables, status, and I/O data with each data sweep. The redundant link uses GE Fanuc's new PACSystems Control Memory Xchange for the fastest synchronisation, with little or no impact on the application program. PACSystems High Availability has been available from the second quarter 2004.
For more information contact Daniel Coetzee, business manager, Sub-Saharan Africa, GE Fanuc Automation, 031 583 2602, [email protected], www.gefanuc.com
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