How can you design a redundant control system architecture that meets industry standards?

1 Redundancy types

There are different types of redundancy that can be applied to the control system architecture, depending on the level, scope, and mode of redundancy. Level refers to the hierarchy of the control system, such as field, controller, or network level. Scope refers to the number and diversity of the redundant components, such as 1-out-of-2, 2-out-of-3, or heterogeneous redundancy. Mode refers to the way the redundant components operate, such as hot standby, cold standby, or load sharing. Each type of redundancy has its own advantages and disadvantages, and should be selected according to the requirements and constraints of the application.

2 Redundancy management

Redundancy management is the process of coordinating and controlling the redundant components and ensuring their consistency and integrity. It involves tasks such as fault detection, fault identification, fault isolation, fault recovery, and fault masking. Redundancy management can be implemented using different strategies, such as centralized, decentralized, or distributed. Each strategy has its own benefits and challenges, and should be aligned with the redundancy type and the system architecture.

3 Industry standards

Industry standards are sets of rules, guidelines, and specifications that define the best practices and requirements for designing, implementing, and testing redundant control system architectures. They can help to ensure the compatibility, interoperability, and quality of the control system components and communication protocols. Some of the most common and relevant industry standards for redundant control system architectures are IEC 61508, IEC 61511, IEC 62443, ISA 84, and ISA 99. Each standard has its own scope, objectives, and recommendations, and should be followed according to the application domain and the regulatory context.

5 Maintenance and monitoring

Maintenance and monitoring are the activities of keeping and improving the condition, efficiency, and security of the redundant control system architecture. They can help to prevent or reduce the occurrence and impact of failures, degradation, or attacks in the control system. Maintenance and monitoring can be performed using different techniques, such as preventive, predictive, or corrective maintenance, and online, offline, or remote monitoring. Each technique has its own benefits and drawbacks, and should be applied according to the maintenance and monitoring policies and procedures.

By following these aspects and challenges, you can design a redundant control system architecture that meets industry standards and satisfies the needs and expectations of the stakeholders. A redundant control system architecture can enhance the reliability, safety, and availability of the industrial process, and reduce the risks and costs of downtime, damage, or accidents.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?