Rockwell Automation LOGIX User Manual
LOGIX HOT BACKUP
BEGIN
SOLUTIONS
Reduce unplanned downtime with Logix
redundant control solutions
Downtime is
a certainty.
What’s the plan?
Lost production is inevitable, so planning for outages is critical.
Part of that planning process should include an understanding of control system
reliability. This has a different meaning in every industry, so going back to the
basics is necessary. Identifying the type of disruption and severity of the outcome
can help you evaluate risk mitigation options should a downtime incident occur.
A good place to start is with a risk assessment. Depending on your specific
manufacturing environment and application, the results of the assessment
can help determine suggested techniques to help keep your people and your
equipment safe.
One of those suggestions may be to build controller redundancy into your
operations. Before diving into the details, what are some of the considerations
in your specic industry and application?
What ’s the plan?
PG 2
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
2
WITH SOME PROCESSES,
REDUNDANT CONTROLLERS
ARE TWICE AS NICE!
Some production environments are continuous
or irreversible and require high availability at
all costs. Disruption of the process could be
catastrophic from both a safety and profitability
perspective. If any failure or stoppage occurs
after production starts, the product is often
scrapped, and the process reinitiated to realize
a quality output. Think life sciences, food and
beverage, pulp and paper, oil and gas, mining,
cement, etc.
Other industries or applications simply can’t
afford to restart their production because it
can take days, weeks, even up to a month to get
back to full operation. A perfect example is the
metals industry. What if a large furnace in a steel
mill experiences a failure? It could take days to
reach a stable operating temperature again so
production can resume.
Although these examples are more aligned with
critical industries where reliability at the highest
levels is required, some applications need high
availability for other reasons, including customer
service. Think baggage handling.
In ALL these cases, what might be the cost of
not implementing redundant control?
What ’s the plan?
PG 2
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
3
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