Safety Instrumented System (SIS)

Transcription

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2 Instrumented System (SIS) Independent system composed of sensors, logic solvers, and final control elements for the purpose of: SIS 1) Shutdown: Automatically taking the process to a safe state when predetermined conditions are violated 2) Permissive: Permit a process to move forward in a safe manner when specified conditions are met 3) Mitigation: Taking action to mitigate the consequences of an industrial hazard Profisafe BPCS Profibus DP Industrial Ethernet Engineering Station PS Operator Station ESD action Trip Point SV PCV PT1 PT2 Pressure Alarm high Pressure High Pressure Alarm Process Control Normal Pressure Low level

3 Traditional Systems Traditional safety systems have implemented internal, proprietary implementations of safety communications for years CPU to I/O communications CPU to CPU communications Industry experts share differing opinions about the viability of today's buses for safety networking Some say hard wire is the only safe way and requires a new standard Some say what we have now will work fine in the process industry The whole industry is interested in a safety fieldbus because users have seen benefits of with their standard control systems and now want the same for their safety systems.

4 Automation & Instrumentation Planning Installation Service Up to 70% space saving + 40% cost saving Terminal blocks Terminal blocks Terminal blocks barrier Cabinet Documentation Commissioning Cabinet PROFIBUS Drive Measurement Remote I/O Measurement

5 Advantages Similar to those for conventional fieldbuses Lower field wiring costs Improved diagnostics Increased uptime and plant utilization resulting from improved asset management Improved maintenance and test data for reporting

6 End-User Requirements Reduced Total Cost of Ownership CAPEX (Hardware, Footprint, Commissioning, Power Consumption) OPEX (Advanced diagnostics, Reduced test interval) SIL 2 and 3 applications Password protected access to field devices Support for discrete signals (e.g. switches, lights, PB s, etc.) System Approach to Asset Management SIS and Non-SIS Diagnostics Hybrid system architecture SIS & traditional hardware Proof test guidance (manual, auto, opportunity-based) Logging/documentation of results Failure rate tracking

7 Process ISA S Each individual field device shall have its own dedicated wiring to the system clause Standard does not address technologies not currently in use (ie. es), but revisions will address technologies as they become available IEC / ISA S Allows a digital bus communication with overall safety performance that meets the integrity of the SIF ( Instrumented Function) it services - clause ISA TR ( ) Technical Report

8 Key Requirements from ISA TR Certified safety fieldbus communication protocol to support the highest Integrity Level (SIL) of the Instrumented System (SIS) Interoperable and non-proprietary -related and non-safety-related devices may coexist provided non-safety-related devices are non-interfering Diagnostics implemented in a manner transparent to the user and capable of reporting to asset management system Fault tolerance should be optional Sufficient security to prevent inadvertent changes Online replacement of devices possible System shall be testable Sufficiently fast response time

9 Available Technology Machine AS-i Safe Interbus-S DeviceNet Pilz BUS p ABB AC31 Process FF-SIS

10 Process

11 is a application layer (profile) that describes the communications between fail-safe devices Version 1.0 was published for review in 1999 Current version (V1.30) published in June 2004 Supports safe communication over open standard buses PROFIBUS (DP, PA) and PROFINET TUV Certified to IEC SIL 3 / EN Cat 4 850,000+ nodes installed

12 Interoperability slave software development is supported by a generic driver Distributed as ANSI C source code as part of a starter kit Use of this driver saves development resources and time and ensures interoperability TÜV approved this driver for SIL 3 requirements Test Specification Proven device certification process (7 independent test labs)

13 Same Protocol Supports PROFIBUS (DP, PA) & Profinet Fail-safe data Standard data Fail-safe data Standard data PROFIBUS DP PROFINET IO layer Standard bus protocol layer Standard bus protocol Black channel" PROFIBUS or PROFINET

14 Communications Layer Standard- I /O e.g.. Diagnosis Input -Layer Control -Layer "Black Channel": ASICs, Links, Cables, etc. are not safety relevant Non safety critical functions, like e.g. diagnosis Output -Layer Standard Control "": Parts of the safety critical communications systems: Adressing, Watch Dog Timers, Sequencing, Signature, etc. relevant, but not part of the -Profils: I/O and the Control Systems 7 2 1

15 Message Format Standard-Message-Frame S S S S S S *) 2 Byte for a max. of 12 Byte F I/O data 4 Byte for a max. of 122 Byte F I/O data F-I/O-Data Status / Controlbyte Sequence Number Sender based Counter CRC across F-Data and F-Parameter Max. 12 / 122 Bytes 1 Byte 1 Byte 2/4 Bytes *) Standard- I/O-Data (240/238 - F-Data) Max. 244 Bytes DP-Data

16 Comm Failures and Remedial Measures Failure type: Repetition Remedy: Consecutive Number X Time Out with Receipt Codename for Sender and Receiver Data Consistency Check (CRC) Deletion Insertion Resequencing X X X X X X Data Corruption Delay X X Masquerade (standard message mimics failsafe) FIFO failure within Router X X X X From: Position paper DKE-AK The measures shall be executed and monitored inside one fail-safe unit

17 Fully Integrated Communications B+B B+B IE/PB Link SIMATIC S7-300F DI First Process DI AO Redundant PROFIBUS PA PA Devices

18 Fully Integrated Communications Standard Components are Non-Interfering with Components Non-Interfering Program Fail-Safe Program CPU + Fail-Safe Software (ProfiSafe) PROFIBUS-DP Standard PROFIBUS DP Communication via Fail-Safe Protocol (ProfiSafe) Fail-Safe I/O Standard I/O Fail-Safe I/O Modules for safety signals Standard I/O modules for non-safety signals

19 with Profisafe Flexibility to choose the redundancy levels to fit each Instrumented Function (SIF) DI DI Mix and Match to meet the goals of the application 2oo2D (Dual 1oo1D) 1oo1D 2oo3 1oo2D 1oo3 3oo3

20 with Profisafe DI

21 with Profisafe DI Make any component redundant

22 with Profisafe DI Make any component redundant Physically separate redundant resources DI

23 with Profisafe DI DI Make any component redundant Physically separate redundant resources Mix and match redundancy

24 with Profisafe DI DI Simplex Dual Make any component redundant Physically separate redundant resources Mix and match redundancy Triple

25 with Profisafe DI DI Simplex Dual Make any component redundant Physically separate redundant resources Mix and match redundancy Tolerate multiple faults with no impact on safety Triple

26 with Profisafe Field Device redundancy can be designed to achieve safety and availability goals CPU/IO safety is not dependant on redundancy When components are SIL3-capable DI 1oo1D 2oo2 TT 1oo2 Valves 2oo3 PT

27 with Profisafe Field Device redundancy can be designed to achieve safety and availability goals CPU/IO safety is not dependant on redundancy When components are SIL3-capable DI Redundancy only for availability DI 2oo2D 2oo2 TT 1oo2 Valves 2oo3 PT

28 with Profisafe IO and Field Device redundancy can be matched to: Minimize cost Maximize availability DI DI 2oo3 2oo2 TT 1oo2 Valves 2oo3 PT

29 And Now with PROFIBUS PA Redundancy Ring Architecture with Active Field Distributor PROFIBUS DP Automatic Bus Termination S7-400FH DP/PA Coupler, redundant AFD AFD AFD 2oo3 1oo2 Safe communication down to the field device and high availability on one segment

30 with Profisafe Simplex DI Ultimate flexibility to choose the redundancy levels to fit the Instrumented Function (SIF) Mix and Match to meet the goals of the application CPU/IO safety is not dependant on redundancy DI Dual When components are SIL3-capable Redundancy only for availability IO and Field Device redundancy can be matched to: Meet Target Performance Maximize availability Minimize cost Triple

31 for Profibus with Integrated Control and Systems for FPSO Facilities

32 What is an FPSO? Floating Production Storage and Offloading Oil, Gas, Water processing systems Gas used for fuel gas, gas lift, gas re-injection, gas export Water is used for water injection

33 FPSO Control Systems Process control (PCS) Production inlet Fiscal metering Heating and cooling Oil & Gas separation Gas compression Water injection Gas dehydration Power generation Water treatment Gas re-injection systems Process shutdown (PSD) - SIL1 or SIL2 Emergency shutdown (ESD) SIL3 system Fire and Gas (F&G) Vessel utilities Monitoring and alarm system Ballast monitoring and control Cargo offloading Standby motor control Power management Load, stress and stability calculations Bilge control Engine room Boiler regulatory control Boiler safety / burner management

34 Traditional Automation and Electrical Process Skids Power Distribution Scrubber Subsea system Supply of process steam Condensate supply Water Injection Process Supply of general process load Fuel gas supply MV UPS LV Rotating Equipment ST M G P Telecoms Routers Satellite system Automation & Instrumentation Process Control Local Control Local Control System ESD & F&G GT G Radio/UHF/PABX M C PC Nettwork Local Control GT G Instrumentation Local Control M C

35 Networks for Integration of FPSO Packages ICSS Industrial Ethernet ICSS Operator Stations Central Control Room (CCR) Profibus Profibus I/O AS Remote I/O I/O AS AS AS AS I/O Remote I/O Gas Compression Seperation Water Injection Produced Water Treatment E-house Power Generation Boilers

36 Process Skids Traditional Separation Subsea system Power Distribution MV Supply of process steam Scrubber Condensate supply UPS Water Injection Process Supply of general process load Fuel gas supply LV Rotating Equipment ST M G P Telecoms Routers Satellite system Automation & Instrumentation Process Control Local Control Local Control System ESD & F&G GT G Radio/UHF/PABX M C PC Nettwork Local Control GT G Instrumentation Local Control M C

37 MV Scrubber Supply of process steam Condensate supply Water Injection Process Supply of general process load Fuel gas supply UPS LV ST G Telecoms Process Control Local Control System M P Process Local Control ESD & F&G M C GT G Local Control GT G Instrumentation Local Control M C

38 Partially Integrated. Telecoms Supply of process steam Condensate supply Fuel gas supply GT G MV Process ST G M C M P UPS LV M Scrubber C Water Injection Process Supply of general process load System ESD & F&G Local Control Local Control GT G

39 Integrated Automation Telecoms Supply of process steam Condensate supply Fuel gas supply GT ST G M C G MV Process M P UPS LV M Scrubber C Water Injection Process Supply of general process load System ESD & F&G Local Control Local Control GT G

40 The Totally Integrated Solution. Telecoms Telecoms Supply of process steam Condensate supply Fuel gas supply GT GT ST G M C G G MV Vessel Management, & Process Control System ESD and F/G M P UPS LV M Scrubber C Water Injection Process Supply of general process load Onshore Control Service and operation Control Panel

41 Typical FPSO ICSS Architecture FGS

42 fieldbus is an emerging trend in process safety applications Technology to implement fieldbus in safety applications is available today Implementing safety fieldbus technology can provide distinct advantages over hardwired solutions: Improved diagnostics Remote access to instrument data for asset management Data to support reporting requirements (test and maintanance records) Ability to design multiple fault tolerant Instrumented System

43 Thank you - Questions? HP: stephen_burke@siemens.com Presenter: Stephen Burke Siemens Singapore