IEC SC65C WG15

Parallel Redundancy Protocol

an IEC standard for a seamless redundancy method applicable to hard-real time Industrial Ethernet Abstract: description of a method to implement highly available automation networks by using parallel redundant networks, standardized in IEC 62439-3 Clause 4

picture from shawnhallwachs' photostream

Prof. Dr. Hubert Kirrmann, ABB Corporate Research, Switzerland 2011 March 21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Summary

PRP (IEC 62439-3 Clause 4) - Ethernet redundancy method independent of any industrial Ethernet protocol

- Seamless switchover and recovery in case of failure supports real-time communication

- Supervises redundancy continuously for device management - Suitable for hot swap - 24h/365d operation in substations

- Allows mixing devices with single and double network attachment on the same LAN
- Allows to connect laptops and workstations to the network with standard Ethernet adapters - Supports any topology

- Suited particularly for substation automation, high-speed drives and transportation.

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Highly available automation networks

Automation networks require a high availability to ensure continuous plant operation. Beyond high quality elements and good maintenance, availability is increased by redundant elements (links, switches, interfaces or devices) activated automatically in case of failure. Redundancy activation after a failure often costs recovery time, during which the network is unavailable. The plant must be able to tolerate such interruption of service. This applies to fault situations, removal and insertion of redundancy.

IEC SC65C WG15 standardized in the IEC 62439 Suite several methods to implement high availability networks, divided into two main categories:
- redundancy in the network, e.g. redundant rings, with devices attached to a single switch only (singly attached devices), while the switches (bridges) implement redundancy (e.g. using RSTP)

- redundancy in the devices, using devices with two network interfaces attached to redundant networks (doubly attached devices)
This presentation describes the Parallel Redundancy Protocol (PRP), a redundancy in the devices method, that provides bumpless switchover in case of failure or reintegration.
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP principles

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks
PRP A frames PRP B frames standard frames

PRP Principle Network Architecture

source DANP

SAN = Singly Attached Node DANP = Doubly Attached Node using PRP DANP SAN

switch

switch

local area network A

switch switch

local area network B

switch switch

SAN

DANP destinations

DANP

DANP

DANP

DANP destinations

SAN

SAN

Two Ethernet networks (LANs) , completely separated, of similar topology operate in parallel. Each doubly attached node with PRP (=DANP) has an interface to each LAN. A DANP source sends a frame simultaneously on both LANs. A DANP destination receives in normal operation both frames and discards the duplicate. A singly attached destination only receives one. If a LAN fails, a DANP destination operates with the frames from the other LAN. IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP characteristics

PRP allows to attach nodes to a network by redundant network interfaces and links: Addresses high availability networks tolerating any single network component failure Provides seamless switchover (zero nanoseconds) in case of network failure. Transparent to the application Can be used with any Industrial Ethernet on layer 2 or above Does not rely on higher layer protocols to operate or be configured Allows nodes not equipped for redundancy to communicate with redundant nodes Uses off-the shelf components (network interfaces, controllers, switches and links) Can be used with any topology (tree, ring,)

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP Node Operation

source node X destination node Y applications publisher/ transport layer subscriber network layer send receive

upper layers link layer link redundancy entity (LRE) Ethernet controllers transceivers LAN A LAN B

applications publisher/ transport layer subscriber network layer send receive

Tx A Rx

Tx B Rx

Tx A Rx

Tx B Rx

A B

send on both LANs: the LRE sends each frame simultaneously on LAN A and LAN B. transfer: Frames over LAN A and B transit with different delays (or could not arrive at all)

receive from both LANs: the node receives both frames, the LRE between link layer and Ethernet controllers handles the frames and can filter duplicates. Both lines are treated equal.
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Why a layer 2 redundancy ?

Many Industrial Ethernet networks operate with a layer 2 (Link Layer) protocol. One motivation for this is the use of the publisher-subscriber method, that relies on broadcast of source-addressed data within the MAC broadcast domain.

This excludes a redundancy scheme based on routers (Layer 3).

Each node in PRP has the same MAC address on both network interfaces. Therefore, management protocols such as ARP operate as usual and assign that MAC address to the IP address(es) of that node. Tools based on SNMP also operate as usual.

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Typical Industrial Ethernet stack

application application application

API Hard Real-Time stack Soft Real-Time stack

Layer 2 Publisher /Subscriber

SNTP, PTP, (SNMP)

Layer 7 publisher/ subscriber (producer/ consumer)

Client / Server services

UDP IP Priority tag Link Layer MAC/PHY

TCP

ICMP ARP

rapid spanning tree (802.1d)

802.p1 / 802.1Q
PTID=8100

optional priority tagging

PT=0800 Ethernet 802.3 0806

void 802.2

Redundancy methods must operate on Layer 2 (Logical Link) to address Industrial Ethernets with hard real-time stacks built on Layer 2, such as IEC61850.
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Attachment of non-redundant nodes

SAN

10

local area network A inter-switch link switch switch inter-switch port switch edge ports switch switch

local area network B

switch leaf link

SAN

leaf link redbox

SAN

DANP

DANP

DANP

DANP

DANP

SAN

SAN

DANP = Doubly Attached Node with PRP

Singly attached nodes (SAN) are preferably all attached to the same network. Network traffic is asymmetrical, but this does not affect redundant operation. Singly attached nodes can also be attached through a redundancy box (red box)
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP cabling rules: keep the LANs separate

11

Party-Line topology (switch element in nodes)

LAN A LAN B
both cables can run in the same conduct if common mode failure unlikely

Star topology (only one switch shown)

switch A

switch B

common mode failures cannot be excluded since wiring comes close together at each device
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

How PRP discards duplicates

12

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Filtering: duplicate discard and duplicate accept

13

A node receives the same frame twice if both redundant LANs are fault-free. There is in theory no need to discard duplicates at the link layer.

Any communication or application software must be able to deal with duplicates, since switching networks (e.g. 802.1D RSTP) could generate duplicates:
Most applications work on top of TCP, which was designed to discard duplicates Applications on top of UDP or Layer 2 protocols (publisher/subscriber) must be able to ignore duplicates because they rely on a connectionless communication.

PRP can operate without duplicate filtering (Duplicate Accept mode, used for testing). PRP uses a Duplicate Discard mode, helpful:

1) to offload the processors, especially when communication controllers are used.

2) to supervises redundancy, bus errors, partner nodes and topology. This turns out to be the major motivation.
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Discarding duplicate frames with a sequence counter original Ethernet frame

14

preamble

destination

source

LLC

payload

sequence counter

size

PRP suffix

lane

FCS

time

- each frame is extended by a sequence counter, a lane indicator, a size field and a suffix * inserted after the payload to remain invisible to normal traffic.
- the sender inserts the same sequence counter into both frames of a pair, and increments it by one for each frame sent. - the receiver keeps track of the sequence counter for each for each source MAC address it receives frames from. Frames with the same source and counter value coming from different lanes are ignored. - for supervision, each node keeps a table of all other nodes in the network, based on observation of the network. This allows to detect nodes absence and bus errors at the same time.
IEC SC65C WG15 2011 HK 2010-11-21

* not present in PRP-0

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Distinguishing redundant from non-redundant frames

15

The receiver detects if a frame is sent by a doubly attached node running PRP or is sent by a singly attached node with no redundancy trailer.

To this purpose, a receiver identifies the PRP frames using suffix and the size field. If the suffix is present and the last 12 bits of the frame match the size of the payload, the receiver assumes that this frame is a PRP frame and a candidate for discarding.
preamble destination source LLC payload sequence size PRP suffix lane FCS time

In a frame sent by a singly attached node, assuming random data in the payload, there is a probability of 2-28 that the size field matches the payload. However, a frame will not be discarded unless a second frame arrives from the other lane from that same source and with that same sequence number and with the correct line identifier, which is not possible since a singly attached node is attached only to one lane (half network).
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP Why the redundancy trailer works with SANs

16

Putting the redundancy control trailer after the payload allows SANs, i.e. nodes not aware of PRP (singly attached nodes such as laptops) to understand PRP frames.
All singly attached nodes ignore octets between the payload and the frame check sequence since they consider it as padding.

To this effect, all (well-designed) protocols built on layer 2 have a size control field and a separate checksum.
Example IP frame: IP packet
physical end delimiter (phy)
ED

link addresses
48
destination

link
LLC IP adr IP size IP checksum IP payload RCT FCS

48
source

preamble

ignored by IP, treated as padding

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Sequence number build-up

17

There exist two variants of PRP. A network is configured homogeneously as PRP-2010 or PRP.
PRP-2010 (IEC 61439 Clause 3 2010) original specification, obsolete) increments the sequence number for each frame (pair) sent to a particular destination. A frame is uniquely identified by <SA & DA & VLAN & SeqNr>. this connection-oriented scheme allows a duplicate detection based on the drop window algorithm, mentioned in the standard, since the receivers see the sequence number increasing monotonically. PRP (IEC 62439-3 2011, compatible with HSR (IEC 62439-3 Clause 5) increments the sequence number for each frame (pair) sent. A frame is uniquely identified by <SA & SeqNr> Due to switch filtering, a receiver only receives part of the traffic and could see gaps in the received sequence numbers. Detection uses a sequence number table, either attached to the node table or using a hash, like in HSR. This sequence number table must age to avoid aliases (not duplicates).
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Principle of duplicate detection

18

The method used to discard duplicates is not (any more) specified since it depends on the implementation (e.g. FPGA or software), but it is replaced by rules: Any scheme that detects duplicates must fulfill the requirements:
1) 2)

never discard a legitimate frame as a duplicate discard nearly all duplicates (some drop-out are unavoidable)

The receiver keeps a list of frame identifiers (as table or numbering scheme). The size of that list depends on the expected traffic.

An entry in the sequence number list resides at least TresideMin and at most TresideMax
(values are implementation-dependent)

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Duplicate detection: wrap-around of the sequence number

19

The duplicate discard bases on sequence numbers to uniquely identify a frame. The sequence number has a fixed size (i. e. 16 bits) so it wraps around after a number of frames (65535). The minimum wrap-around time t wrapMin happens when a node sends a series of consecutive minimal length frames (an unrealistic, worst-case) The minimum wrap around time can calculated: @ 100 Mbit/s : 6.72 s 65536 = 440 ms @ 1 Gbit/s: 0.67 s 65536 = 44 ms. This means that a legitimate frame is detected as duplicate when the second frame of a pair is delayed so that it arrives within that time of the legitimate frame (see next slide).

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Duplicate Detection in function of skew

t wrapMin = 440 ms
alias frame same seqNr, new contents

20

SeqNr = X A B
t skew1 < t resideMin

t resideMin

t resideMax

t residenceMax

SeqNr = X

t skew < t residenceMax

tresideMin < t skew1 < t resideMax

t skew1 > t resideMax

Case 3 SeqNr out of table Case 2: duplicate SeqNr possibly in table treated as new frame duplicate -> SeqNr now in table, sometimes not detected, only safe if treated as new tresidenceMax < twrapMin Rule for reliable discard: tskew < tresideMin Rule for probable discard: tskew < tresideMax Rule for safe accept: t residenceMax < taliasRepMin ideally: t residenceMin = t residenceMax = t wrapMin /2 Proposal: t residenceMax = 500 ms
IEC SC65C WG15 2011 HK 2010-11-21

Case 1: SeqNr is in table duplicate always detected if tskew < tresideMin

Case 4 SeqNr still in table next alias frame discarded as duplicate danger !

Case 5 SeqNr in table, duplicate detected on wrong alias

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Frame formats used in (all) Industrial Ethernets

RSTP traffic
802.2 / 802.3
1518 octets

21

IP traffic
Ethernet II
1518 octets

Prioritized or VLAN traffic

801.d (VLAN)
1522 octets

destination

destination

destination

source
<= 1518 octets

source

source

protocol type >x0600

length < x0600 DSAP SSAP LLC (802.2)

ETPID = x8100 TCI, CFI protocol typetype protocol >x0600

<= 1522 octets

LPDU = 46..1500 octets (TCP, UDP, ICMP)

LPDU = 42..1496 octets LPDU = 42..1500 octets

checksum

checksum

checksum
= 6.72 s..123.04 s @100 MBit/s

Most Industrial Ethernet allow a mix of 802.2, 802.3, etcresulting in 3 different frame types...
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP frames: redundancy control after the payload

Ethernet II
802.3/802.2 (e.g. BPDU)
1518 octets

22

802.1Q (VLAN)
1522 octets

1518 octets

destination

destination

destination

source protocol type >x0600

source length <x0600 DSAP SSAP LLC

source ETPID = x8100 TCI, CFI = x8100 protocol typetype protocol >x0600

<= 1518 octets

<= 1522 octets

LPDU = 46..1496 octets

LPDU = 42..1492 octets

LPDU = 42..1490 octets

appended redundancy control trailer

sequence number lane size PRP suffix checksum

sequence number lane size PRP suffix checksum

sequence number lane size PRP suffix checksum

The additional six octets could generate oversize frames of more than 1522 octets. Although these frames are accepted by all certified switches (up to 1536 octets), some older bus controllers do not accept oversize frames, and therefore the sender should reduce the payload by playing on the LSDU size in the network layer (if the frame is going to be tagged).
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Is appending a redundancy trailer in line with 802.3 ?

23

PRPs Duplicate Discard mode requires that frames be stretched by 6 octets.

All protocols must be able to deal with data in the frames after the payload, since padding is part of the Ethernet protocol.

E.g., IP has its own size control and checksum data after the IP payload are ignored.
The maximum size of the payload must be reduced by six octets to match the size of 1500 octets foreseen by IEEE 802.3-2002 4.4.2.1 This would not be necessary for the switches, since all commercial switches permit longer frames to support double VLAN tagging. However, some older Network Interfaces for PCs do not accept longer frames. Network analyzers can deal with PRP, the corresponding PRP extension already has been appended to EtherReal (http://www.ethereal.com). In networks where this could become a problem, the source should reduce of the LSDU size, e.g. at the IP level.
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Redundancy Control Trailer and Padding

24

Small frames use padding to meet the minimum frame size of 64 octets. Since padding can be introduced by switches, the sender should always insert the padding itself to reduce the decoding burden (otherwise, the receiver has to search backwards for a matching field)
Padding introduced automatically: do not use
64 octets

preamble

destination

source

LLC

LSDU

sequence

size

PRP suffix

line

padding

FCS time

Padding inserted by the sender

preamble destination source LLC

64 octets

LSDU

padding

sequence

size

PRP suffix

line

FCS time

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Why a size field is also useful

25

Ethernet frames have, contrary to IEC 8802.3 frames, only a Hamming Distance of 1 against synchronization errors (frames truncation), since they do not contain a length field.

preamble 01010101

destination

source

PT

LPDU LPDU

FCS

truncation error: the last 32 bits are treated as CRC preamble 01010101 destination source PT LPDU FCS ? truncated FCS time

only the application (if it is aware of it) can detect the problem....
"We detected a mismatch between TCP and Ethernet checksum in up to one frame in 400 (Siggcom 2000, J. Stone & C. Patridge @standford, bbn)

To improve protection of the frames, a size field is appended to the frames.

A node that receives a PRP frame from a known partner with incorrect size can flag an error.
01010101 destination source LLC LPDU line sequence size PRP-suffix FCS time

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP network management

26

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Network supervision and detection of lurking faults

27

PRP checks continuously all paths. In order not to rely on application cyclic data for this, each DANP sends periodically a supervision frame that indicates its state.

The period is relatively long (some seconds) since the supervision frame is not needed for switchover, but only to check dormant redundancy.
All nodes keep a node table of all detected partners and registers the last time a node was seen as well as the number of received frames from each other node over both interfaces. The duplicate discard mode allows to keep track of all nodes in the network. Changes to the topology are communicated over SNMP or to the Link Management Entity.

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks
doubly-attached nodes 172.16.1.11 172.16.1.12

Network management
COTS NM tool
172.16.1.14 172.16.1.14

28

singly-attached nodes 172.16.1.66

node 1

node 2

"red box"
172.16.1.129

node 4

node 65

node 66

switch A
LAN A

LAN B switch B1
172.16.1.193

switch B2 switch B3
172.16.1.195

172.16.1.192

Switches are single-attached devices and have different IP addresses on each LAN, although their function can be the same as that of a corresponding switch on the other network. Each PRP node has an SNMP agent to keep track of redundancy.
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP technology

29

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

Maturity of technology

30

PRP is supported by ABB and the Zurich University of Applied Sciences at Winterthur (ZHAW).
ABB products supporting PRP are certified for on-site operation and gathered field experience. ZHAW built an independent Linux DANP using only the IEC document as specification. Interoperability between VxWorks, Linux and Windows implementations was tested in 2008. Several companies are using PRP in 2011.
PRP in Factory Acceptance Test - picture courtesy ABB

LAN_A

PRP is here handled by the main processor. Co-processor or FPGA can execute PRP as well.

LAN_B

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP: Pros & Cons

31

+ deterministic, seamless switchover (zero switchover time)

+ application-independent, suits any Industrial Ethernet network.

+ uses standard switches and protocols unmodified (ARP, DHCP, TCP/IP) + allows attachment of nodes with any single port node to the network (with no redundancy) + does not breach the fail-independence of the redundant networks

+ supervises constantly the redundancy in duplicate discard mode (both LANs are active)
+ monitors actual topography (over network management / SNMP) + compatible with IEEE 1588 a redundant clock profile is defined

- requires complete doubling of the network, two Ethernet controllers and a special driver per node (about twice the costs but this is the price to pay for any full redundancy)
- restricted to a layer 2 broadcast domain (not a limitation in Industrial Ethernet) - requests that singly attached nodes that need to communicate with each other are connected all to the same LAN (or through a red box) - cost four bytes overhead in a frame but oversize frames should become IEEE standard.
IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

PRP vs. other standards

32

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks

State of standardization and other solutions

33

The Highly Available Automation Networks IEC SC65C WG15 selected PRP and HSR as one of its redundancy methods, along with: MRP (Siemens-Hirschmann) implements redundancy in the network with singly attached devices attached to a ring, with moderate increase in availability and disruption delay of 200 ms-500 ms. It is interesting if the switches are integrated in the devices, but this limits topology to a simple ring of up to 50 switches. CRP (Honeywell/Fieldbus Foundation) implements like PRP redundancy in the devices, offers the same availability as PRP, but has disruption times of 200 ms 2s. It allows to connect singly attached devices to both network halves, but costs aggregated links in the (mandatory) root switches. BRP (Rockwell, OVDA) exhibits characteristics similar to CRP, strives to provide a 20 ms recovery delay by sending a beacon at short intervals CRP (SupCon, China) is a ring redundancy protocol which competes with MRP and uses a tight clock synchronization to support time-slotted real-time traffic. Only PRP and HSR provide zero recovery time.

IEC SC65C WG15 2011 HK 2010-11-21

IEC 62439-3.4 (PRP)

Highly Available Automation Networks
Topology Costs

Comparison with CRP and BRP redundancy schemes

CRP (Fieldbus Foundation) connected meshed unrestricted network duplication + 2 controllers / device + top-level switch with aggregated links special LRE driver two MAC addresses large traffic in top switches BRP (Rockwell) connected meshed hierarchical star network duplication + 2 controllers / device + top-level switches with aggregated links + two beacon nodes special LRE driver co-processor support priority settings large traffic in top switches no multicast filtering traffic burst upon failure yes no PRP (ABB) unconnected, unrestricted

34

network duplication +2 controllers / device

Implementation Restrictions on configuration Restriction on performance

special LRE driver none negligible (4 bytes/frame)

SAN can talk with SAN on other LAN SAN aware of protocol

yes optional SANC, little used

no, except through red box no

Redundancy protocol uses

Error detection on reception Error detection on sending Check inactive port Switch tables actualization

IP frames (opt. intercepted)

missed DiagnosticFrame receive DiagnosticFrame of other port send/receive DF every Tdmi Annunciation frames

IP frames (will change)

missed beacon time-out on partner node TBD for sending Learning frame at switchover

layer 2 frames
missed node annunciation periodic annunciation and and network management no need, both ports active not needed

Table of partner nodes

Network supervision Switchover time
IEC SC65C WG15 2011 HK 2010-11-21 Licenses

yes, configured
SNMP, node tables (Tdmi interval) 200 ms yes

yes, configured by tools

SNMP TBD configured 20 ms (?) free of charge (?)

yes, dynamic
SNMP, node tables zero free of charge