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DOCUMENT TITLE Reliability and availability calculation

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 Reliability and availability calculation

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NATIONAL IRANIAN OIL COMPANY

SOUTH PARS GAS FIELD DEVELOPMENT

PHASE 14

OFFSHORE PLATFORMS

DETAIL DESIGN

DOCUMENT TYPE : SPECIFICATION

DOCUMENT TITLE : Reliability and availability calculation

DOCUMENT NUMBER : SP14-NED-IN-CS-0040

SITE : TOMBAK/ SOUTH PARS GAS FIELD DEVELOPMENT, PERSIAN GULF, IRAN

0 27/12/2015 IFI NEDA F.M A.V S.M S.M

Rev Date Description ORIGINATOR PRPD CHKD APPD Contractor APPD

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 Reliability and availability calculation

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 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

RELIABILITY AND AVAILABILITY :

COMPUTATION OF MTBF S7-400H :

2
( MTBF1001)
MTBF 1002 =
2MDT+2(1-dc)*MTBF1001

MTBF1001 =15 years =131400 hrs

MDT=4 hrs

dc=0.95 %

2
( 131400 )
MTBF 1002 = = 1313200 hrs = 150 years
2MDT+2(1-dc)*MTBF1001

COMPUTATION OF AVAILABILITY FOR S7-400H :

( MTBF1002) 1313200
V= 100% = 100% = 99.9996 %
MTBF1002 + MDT 1313200 + 4

* NOTE : SEE NEXT PAGES

Doc.No: SP14-NED-IN-CS-0040 Page 4 of 12

 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

Characteristic Values of Redundant

Programmable Logic Controllers A
The present appendix presents a brief introduction to the characteristic values of
redundant programmable logic controllers and shows the practical effects of
redundant configuration types by means of a few selected configurations.

In Section You Will Find On Page

A.1 Basic Concepts A-2
A.2 Comparison of MTBFs for Selected Configurations A-4

Doc.No: SP14-NED-IN-CS-0040 Page 5 of 12

 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

A.1 Basic Concepts

The parameters normally used for a quantitative assessment of redundant

programmable logic controllers are reliability and availability, which are described in
further detail below.

Reliability
Reliability is the characteristic of a technical device to fulfill its function during its
operating period. This is usually no longer possible when a component fails.
The criterion frequently specified for reliability is therefore the MTBF (Mean Time
Between Failures). It can be determined statistically by systems that are operating
or by calculating the failure rates of the components used.

Reliability of modules
The reliability of SIMATIC components is extremely high as a consequence of
wide-ranging quality assurance measures in development and manufacture.
The following average values apply to SIMATIC modules:
MTBF of a central processing unit: 15 years
MTBF of an I/O module: 50 years

Reliability of programmable logic controllers

The use of redundant modules prolongs the MTBF of a system to a very large
extent. In connection with the high-quality self-tests and the mechanisms for error
detection, which are integrated in the CPUs of the S7-400H, virtually all errors are
discovered and localized. The diagnostic coverage (dc) is approximately 95
percent.
Starting from the reliability of a single system (1-out-of-1 systems having an
MTBF 1oo1), it is possible to calculate the reliability of the S7-400H as a two-channel
(1-out-of-2) fault-tolerant system from the following formula:
2
MTBF 1oo1
MTBF1oo2 +
2MDT ) 2(1 * dc)MTBF 1oo1

The MTBF of the S7-400H is determined by its MDT (Mean Down Time). This time
consists essentially of the time for error detection and the time required to repair or
replace defective modules.
The error detection time is half the configured test cycle time (by default, 90 min.).
The repair time for a modular system such as the S7-400H is normally four hours.

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Doc.No: SP14-NED-IN-CS-0040
 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

Availability
Availability is the probability of a system being capable of operation at a specified
point of time. It can be enhanced by means of redundancy for example, by using
redundant I/O modules or by using multiple sensors at one sampling point.
Redundant components are arranged such that system operability is not affected
by the failure of a single component. Here, again, an important element of
availability is a detailed diagnostic display.
The availability of a system is expressed as a percentage. It is determined by the
mean time between failure (MTBF) and the mean repair time (MTTR). The
availability of a two-channel (1-out-of-2) fault-tolerant system can be calculated
from the following formula:
MTBF1oo2
V+ 100%
MTBF1oo2 ) MDT

Page 7 of 12
Doc.No: SP14-NED-IN-CS-0040
 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

A.2 Comparison of MTBFs for Selected Configurations

The following sections compare systems having a central I/O.

The following framework conditions are set for the calculation.
MDT (Mean Down Time) 4 hours
Ambient temperature 40 degrees
Buffer voltage is guaranteed

A.2.1 System Configurations With Central I/O

The following system with a standard CPU 417-4 is taken as a basis for calculating
a reference factor which specifies the multiple of the availability of the other
systems having a central I/O compared with the baseline.

Standard and fault-tolerant CPU in single operation

Standard CPU 417-4 Baseline

Mounting
1
rack, UR1
PS 407, 10 A

CPU 417-4
SM 421
SM 422

CPU with high availability 417-4H in Solo mode *) Factor

Mounting rack,
1
UR1
PS 407, 10 A

CPU 417-4H
SM 421
SM 422

*) not possible with firmware version V2.0.0

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Doc.No: SP14-NED-IN-CS-0040
 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

Redundant CPUs in different mounting racks

Redundant CPU 417-4 H in split mounting rack Factor

23
PS 407, 10 A

PS 407, 10 A
Mounting rack UR2-H
CPU 417-4H

CPU 417-4H
SM 421

SM 421
SM 422

SM 422
2 fiber-optic cables

Redundant CPU 417-4H in separate mounting racks Factor

59
PS 407, 10 A

PS 407, 10 A

Mounting Mounting
CPU 417-4H

CPU 417-4H

rack, UR1 rack, UR1

SM 421

SM 421
SM 422

SM 422

2 fiber-optic cables

Page 9 of 12
Doc.No: SP14-NED-IN-CS-0040
 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

A.2.2 System Configurations With Distributed I/O

The following system with two fault-tolerant CPUs 417-4 H and a one-sided I/O is
taken as a basis for calculating a reference factor which specifies the multiple of the
availability of the other systems with a distributed I/O compared with the baseline.

Redundant CPUs with a single-channel, one-sided or switched I/O

One-sided, distributed I/O Baseline

2 fiber-optic cables 1
PS 407, 10 A

PS 407, 10 A
CPU 417-4H

CPU 417-4H

ET 200M
IM 153-1

SM 322
SM 321

Switched distributed I/O Factor

2 fiber-optic cables
3 or 12 *
PS 407, 10 A

PS 407, 10 A
CPU 417-4H

CPU 417-4H
DP

DP

ET 200M
IM 153-2
IM 153-2

SM 322
SM 321

* A factor of 3 applies to the condition when the failure of an I/O module has resulted in the entire system
stopping. A factor of 12 applies when the failure of an I/O module has not resulted in the entire system
stopping.

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Doc.No: SP14-NED-IN-CS-0040
 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

Redundant CPUs with redundant I/O

Redundant one-sided I/O Factor

2 fiber-optic cables 65
PS 407, 10 A

PS 407, 10 A
CPU 417-4H

CPU 417-4H
DP

DP

ET 200M ET 200M
IM 153-1

IM 153-1
SM 321

SM 321
SM 322

SM 322

Redundant switched I/O Factor

2 fiber-optic cables 70
PS 407, 10 A

PS 407, 10 A
CPU 417-4H

CPU 417-4H
DP
DP

IM 153-2
IM 153-2
SM 321
SM 322

Active
backplane bus
IM 153-2
IM 153-2
SM 321
SM 322

Page 11 of 12
Doc.No: SP14-NED-IN-CS-0040
 SOUTH PARS GAS FIELD DEVELOPMENT PROJECT
PHASE 14 OFFSHORE PLATFORMS
(Reliability and Availability Calculation)

A.2.3 Comparison of System Configurations With Standard and

Fault-Tolerant Communications

The following section shows a comparison between standard and fault-tolerant

communications for a configuration consisting of a fault-tolerant system, a
fault-tolerant CPU 417-4 H and a single-channel OS.
By comparison, only the communication components CP and cable were taken into
account.

Systems having standard and fault-tolerant communications

Standard communications Baseline

1
S7-400 with
Single-user OS S7-400H system CPU 417-4H

Fault-tolerant communications Factor

83

S7-400 with
Single-user OS S7-400H system CPU 417-4H

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Doc.No: SP14-NED-IN-CS-0040