24.06.2025

In modern industrial automation systems, reliability is the foundation of production continuity and operational safety. Ensuring this reliability requires not only attention to technical aspects and a robust architecture but also proper maintenance planning and the use of redundancy. It’s precisely such systems that ensure uninterrupted operation—even when a component fails..

Redundancja może przybierać różne formy. Najprostsze rozwiązania, określane jako cold standby, wymagają ręcznego uruchomienia zapasowego komponentu dopiero po wykryciu awarii. Bardziej zaawansowane systemy wykorzystują tryb warm standby, w którym zapasowy komponent pracuje w stanie gotowości i może niemal natychmiast przejąć działanie. Najwyższy poziom niezawodności zapewnia hot standby – tu oba komponenty działają równolegle, a przełączenie następuje automatycznie i nie zakłóca pracy systemu.

A good example of a hot standby solution is the Danfoss VACON® DriveSynch system, which enables the parallel operation of multiple frequency converters. This type of solution is used in high-power applications and has the advantage of allowing maintenance of individual modules without interrupting system activity.

Redundancy – Why Is It Worth It?

Is redundancy necessary? In industry, it’s not just a technical safeguard—it’s a strategic investment that reduces the risk of production losses and increases overall process safety. The benefits of implementing redundant solutions go far beyond technical aspects. Above all, they translate into maximum system availability, helping enterprises avoid production downtime and associated financial losses. Automatic switchover to backup systems minimizes the risk of unexpected failures that could halt an entire production line, significantly improving safety levels.

Redundancy is not limited to hardware. Modern control systems also allow for redundant communication paths and mechanisms for function takeover by backup units. As a result, the continuity of system operation can be maintained even in the event of failures in key control logic components.

Redundancy also brings business benefits: it ensures operational continuity, provides greater cost control, and reduces the risk of unplanned downtime—all directly affecting a plant’s efficiency and competitiveness. Redundant solutions are now used across many industries—not just high-demand sectors like energy or chemicals, but also in automotive and food industries, where continuity and operational safety are business priorities.

How to Successfully Implement Redundant Solutions?

Implementing redundancy comes with specific challenges. The most prominent are capital expenditures—doubling infrastructure means higher spending on equipment, licenses, and implementation. The more advanced the system, the more complex the architecture, which requires experience both in design and later service maintenance.

In this context, the advantages of a modular approach become clear—it enables easier system expansion and simplifies maintenance management. Identical modules allow for quick replacement without the need to stock multiple variants of spare parts.

The decision to invest in redundancy should follow a thorough analysis of the plant’s real needs and capabilities—ideally performed with an experienced technology partner. Even the best redundancy system won’t deliver if we don’t ensure full synchronization between primary and backup components. This requires specialized diagnostic tools and an integrator capable of implementing such solutions effectively using their expertise.

Rely on Experience

As an experienced integrator, we specialize in designing and implementing advanced control and process visualization systems using redundant architectures tailored to our clients’ needs. Our offer includes solutions based on the Siemens PCS 7 system, which enables the creation of scalable, secure, and reliable systems for various industrial sectors.

We’ve completed implementations in power plants, where DCS redundancy ensured uninterrupted power delivery. We supported chemical plants where SCADA system continuity minimized the risk of uncontrolled chemical reactions. In the food industry, Control-Service solutions provided continuous monitoring of production parameters, directly impacting food quality and safety.

We also propose solutions involving seemingly redundant pumps or inverters—as in our collaboration with the Carlsberg Group’s brewery in Brzesko. There, we developed a redundant control system for a cascade of three 55 kW pumps using two inverters, a soft starter, and a pressure switch. The system maximizes safety by ensuring water supply for production even during failures.

We combine technology with expert consulting and comprehensive service to deliver not only equipment, but real business value for companies prioritizing reliability and operational continuity. Have questions or need support? Contact us.