Triconex’s Triple Modular Redundancy (TMR) Architecture

Overview of Triconex

Triconex, a Schneider Electric division, is a leading provider of innovative systems and services designed for safety, critical control, and turbomachinery applications. Known for its patented Triple Modular Redundancy (TMR) technology and TriStation software, Triconex focuses on industrial safety solutions. To date, Triconex has over 11,500 installations worldwide, making it the largest TMR safety solutions supplier globally.

Company Background and History

Triconex originated in 1983, founded by Jon Wimer in Santa Ana, California, with a focus on improving safety and reliability in critical industries. Wimer, together with industry expert Peter Pitsker, crafted a business plan targeting high-stakes industries such as petrochemicals and oil. Notably, investor Chuck Cole and his attorney, future Los Angeles Mayor Richard Riordan, provided the initial funding. Although early challenges nearly halted the company’s progress, the leadership of CEO William K. Barkovitz helped secure its market dominance. Eventually, Triconex was acquired by SIEBE in 1994 for $90 million, marking a key milestone in its growth.

The Development of Tricon System Technology

In 1986, Gary Hufton led a team that developed the first Tricon system. Shortly after its release, Exxon became a significant early customer, and Honeywell agreed to distribute Triconex systems, providing greater visibility and adoption. Many engineers who started at Triconex, including Phil Huber and Dennis Morin, went on to make their mark in the industry; both founded Wonderware, now a leader in Human Machine Interface (HMI) technology.

Triconex’s Triple Modular Redundancy (TMR) Architecture

Triconex systems operate on a TMR architecture, which prioritizes safety and uninterrupted operations in industrial environments. This architecture offers a high level of fault tolerance by using three separate data paths for input, processing, and output, effectively creating a fail-safe operation. Each input module sends data to three Main Processors, which synchronize over a high-speed TriBus. With these design elements, Triconex maintains accurate data transfer and application execution, even in adverse conditions, which is essential for industries with high reliability requirements.

Core Components of the Triconex System

The Triconex system comprises several key components that contribute to its reliability and flexibility:

• Main Processor Modules: These operate in a triple-redundant configuration, ensuring fail-safe operation.
• Communication Modules: These facilitate seamless communication within the system and with external systems.
• Input and Output Modules: Supporting both analog and digital I/O with hot standby capabilities, these modules increase system resilience.
• Power Supply Modules: Redundant power supply modules allow for continuous operation.
• Chassis and System Cabinets: Modular backplanes and cabinets ensure effective housing for system components.
• Marshalling Cabinets: These provide standardized connections between field instruments and the Triconex system.
• Human-Machine Interface (HMI): HMI modules allow operators to monitor system events in real time.
• Engineering Workstation (EWS): This workstation enables users to program, monitor, and troubleshoot the system efficiently.

Supported Programming Languages and Software Tools

Triconex systems support multiple programming languages and tools, enabling flexibility across applications:

• Function Block Diagram (FBD)
• Ladder Diagram (LD)
• Structured Text (ST), which closely resembles Pascal
• Cause and Effect Matrix Programmable Language (CEMPLE) for specific safety logic programming

Additionally, the system provides Sequence of Events (SOE) recording and a Diagnostic Monitor for detailed, real-time monitoring and error analysis, which aids in early issue detection.

Industries and Applications Served by Triconex

Triconex’s TMR systems are widely used in industries that require safety-critical solutions, including:

• Petrochemicals and Refining
• Oil and Gas (Upstream and Midstream)
• Chemicals and Specialty Chemicals
• Power Generation
• Pharmaceuticals

Certified to meet the international IEC61508: 2010 standards for SIL 3 applications, Triconex systems are integral to:

• Emergency Shutdown (ESD) Systems
• Fire and Gas (F&G) Control
• Burner Management Systems (BMS)
• High-Integrity Pressure Protection Systems (HIPPS)
• Turbomachinery Control and Protection (TMC)

Reliability and Adaptability in Challenging Environments

With a robust design, the Triconex system performs effectively in harsh environments, where reliability and adaptability are critical. It supports centralized and distributed I/O applications, enabling plant operators to customize installations according to specific site requirements. This level of adaptability enhances both operational efficiency and system resilience.

System Integration and Cybersecurity Features

Integration with major Distributed Control Systems (DCS), including Foxboro Evo™, allows Triconex to work seamlessly within larger process automation setups. The system supports up to 254 nodes for peer-to-peer communication, further enhancing operational continuity. Additionally, the Achilles Level 1 cybersecurity certification provides essential protection against digital threats, ensuring secure and reliable operations.

Maintenance, Lifecycle Support, and Safety Management

To minimize downtime, Triconex systems incorporate built-in diagnostics, redundancy management, and online maintenance capabilities, such as hot spare options. This comprehensive approach allows live system modifications, making it easier to ensure continuous, safe operation. Furthermore, the TriStation suite provides powerful tools for every phase of the safety lifecycle, from initial programming to ongoing diagnostics. These features offer a strong return on investment and make Triconex an excellent choice for companies prioritizing safety and reliability.