ICS TRIPLEX T8160

Description

Product Description

The ICS TRIPLEX T8160 is a high-integrity, fault-tolerant safety controller module designed for the most critical industrial safety applications. As part of the renowned Trusted® system by ICS Triplex, the T8160 module serves as a central processing unit or communication node within a TMR (Triple Modular Redundant) architecture. This architecture is the cornerstone of the ICS TRIPLEX T8160‘s ability to provide continuous, error-free operation even in the event of a hardware failure. Engineered for sectors where system failure is not an option, the T8160 ensures maximum availability and safety integrity.

Product Parameters

• System Architecture: Triple Modular Redundant (TMR) for fault tolerance.
• Safety Certification: Typically complies with IEC 61508 and is suitable for applications requiring SIL 3 (Safety Integrity Level 3).
• Processor: Features synchronized, high-performance processors in each of its three channels.
• Memory: Equipped with sufficient RAM and flash memory for complex safety logic and data logging.
• Communication Interfaces: Includes multiple, redundant communication ports (e.g., Ethernet, proprietary networks) for integration with I/O modules and host systems.
• Operating Temperature: Designed for harsh industrial environments with a wide operating temperature range.
• Diagnostics: Comprehensive built-in self-test (BIST) and diagnostic coverage for all channels.
• Form Factor: Modular design for installation in a Trusted system rack.

Advantages and Features

• Ultra-High Availability: The TMR design allows for “on-line” repair; a single channel can fail and be replaced without shutting down the process.
• Fault Tolerance: Hardware and software voting mechanisms ensure correct output even with an internal fault, eliminating single points of failure.
• Safety & Security: Provides the highest levels of functional safety (SIL 3) and includes features to protect against unauthorized access.
• Robustness: Built to withstand extreme industrial conditions, including temperature, vibration, and electrical noise.
• Seamless Integration: Easily integrates with the broader Trusted I/O system and can communicate with various plant control networks.

Application Cases in Industry

• Oil & Gas: Emergency Shutdown (ESD) systems for offshore platforms and onshore refineries, and Fire & Gas (F&G) detection systems.
• Power Generation: Turbine control and protection in combined-cycle and fossil-fuel plants, as well as burner management systems (BMS).
• Chemical Processing: Critical process shutdown (PSD) systems in large-scale chemical and petrochemical plants.
• Pharmaceutical: Safety interlocks for high-integrity reaction processes where a failure could lead to dangerous situations.

Comparison with Competing Products

Compared to simplex or dual-redundant PLCs (e.g., some Siemens or Allen-Bradley safety controllers), the ICS TRIPLEX T8160 offers a fundamentally higher level of fault tolerance. Competing products may achieve high safety through diagnostics and redundancy but often require a process shutdown upon detecting a fault. The primary competitor is the Emerson DeltaV SIS with its own TMR technology. The T8160 is often noted for its long-proven track record in extreme applications, whereas some newer systems might offer deeper integration with specific DCS platforms. The choice often hinges on legacy system compatibility and specific industry preferences.

Selection Suggestions and Precautions

• Selection Suggestions:
  1. Choose the ICS TRIPLEX T8160 when your application demands continuous operation (high availability) alongside the highest safety integrity (SIL 3).
  2. It is the ideal choice for brownfield expansions or upgrades where an existing Trusted system is in place.
  3. Consider the full system requirements, including compatible I/O modules, power supplies, and engineering software licenses.
• Precautions:
  1. Expertise Required: Configuration, programming, and maintenance require specialized training on the Trusted platform.
  2. Obsolescence Management: As with all specialized hardware, plan for long-term support and spare parts management. Always source from authorized or highly reputable suppliers.
  3. System Design: Safety system design must follow applicable standards (e.g., IEC 61511) and involve a certified safety engineer. The hardware is only one component of a complete Safety Instrumented System (SIS).
  4. Software: Ensure access to the correct version of the configuration and monitoring software (e.g., Trusted Toolset).

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