Safety Expert Council Day 2 Business Strategy t Review

Transcription

1 Safety Expert Council Day 2 Business Strategy t Review ABB Control Technologies October 11, 2012 Slide 1

2 Product Group Safety Growth Strategy Business Plan Execution Focus Areas October 11, 2012 Slide 2

3 Why Evolution? Sales Arguments

4 Are Safety Systems a problem for our customers?.. This is crazy, I can t find spare parts for that system at the same (hardware) revision i running in the plant the vendor can t ensure the spares available are compatible with my system Great! t!if found dthe board dthat twe need din the plant tbut tthe delivery time is 16 to 20 weeks, I guess I should feel lucky I never heard of lifecycle problems, what do you mean the system is obsolete?... if I understand you correctly, you have the software that might work on MS DOS but you don t have a way to provide the OS or drivers for a new computer to run Did you say that the expert will be available in 8 months? Alright, I don t care, I need him on site ASAP, wait how much his the service rate?... October 11, 2012 Slide 4

5 Are Safety Systems a problem for our customers? Digital Technology changed too fast! Spare parts availability Long delivery time and high prices Limited product support Limited technical support Repair capabilities Obsolesce of support equipment (computers) Systems are not compliant with today s safety standards and lack basic functionality and compatibility with other systems or tools October 11, 2012 Slide 5

6 Are Safety Systems a problem for our customers? System Lifecycle View October 11, 2012 Slide 6

7 Are Safety Systems a problem for our customers? System Lifecycle View All PFD calculations assume systems are here! October 11, 2012 Slide 7

8 Are Safety Systems a problem for our customers? Change is also an opportunity New generation of safety systems: Reduce failures rates and downtime Eliminate component wear and tear Enhanced diagnostics Simplify integration Reduce maintenance cost October 11, 2012 Slide 8

9 Why the solution starts with ABB? Global experience in Safety Automation October 11, 2012 Slide 9 ABB is a truly global automation corporation With over 24 Safety Execution Centers (SEC) Relevant domain knowledge tested over time Over 30 years of safety experience Comprehensive solutions for each step of the Safety Lifecycle Expert consulting services TÜV Certified systems TÜV Certified SECs Design, installation and commissioning services Including hot cutover Post-installation lifecycle services Product Lifecycle Policy

10 Why the solution starts with ABB? Safety Execution Centers Safety Execution Center (SEC) TUV Certified SEC October 11, 2012 Slide 10

11 Why the solution starts with ABB? 30+ years of Safety Experience First safety system delivered offshore to the North Sea in 1979 Pioneering engineering efforts Close collaboration between ABB and end-users For an ocean of safety experience you can trust... Long customer relationships with close technical support and system evolution Installed base continuously evolved and migrated to maximize customer value and minimize risk Support throughout system life-cycle from installation to decommissioning October 11, 2012 Slide 11

12 Why the solution starts with ABB? Expert Consulting Services Process Safety Information HAZOP Revalidation PHR Hazard Studies 2 & 3 Service Port ABB FSMS TRAMS LOPA TRAC Achieved SIL ABB FSMS TRAC ABB FSMS October 11, 2012 Slide 12

13 Why the solution starts with ABB? TÜV Certified System Product Safety Certificate Development Department Safety Certificate Safety Manual TÜV Product Service certified all product components of the System 800xA High Integrity offerings October 11, 2012 Slide 13

14 Why the solution starts with ABB? Design, Installation and Commissioning Architectural Design according to target SIL PFD Calculations SIL capability SIS Design Hardware and Software Integration Verification and Validation Functional Safety Assessments Information on operation and maintenance requirements Instructions for testing SRS provides SIL requirement for each SIF Installation and commissioning Functional Safety Management for Design and Build

15 Why the solution starts with ABB? Post-installation Lifecycle Services Overall Safety Validation Periodic Proof Testing Modifications and Retrofits Standard Maintenance System health check Alarm management Service level agreements Certified safety engineers Spares and repairs Competence assurance Training October 11, 2012 Slide 15

16 Why the solution starts with ABB? ABB Product Lifecycle Commitment ABB is the Industry Leader in Lifecycle Management ABB s control systems are designed for continuous evolution. It is ABB s goal to protect our customers intellectual investment (i.e. application software) beyond the lifecycles of the underlying platform products (i.e. hardware and software). ABB will not "Remove from Active Sale" any product or "family" of products until an equivalent replacement to those products is available. Once a product has been removed from active sale, ABB will continue to support the product for at least 10 years, although exceptions to this may occur if components or technologies needed are no longer available to ABB. Within this support period ABB will announce a Last Buy opportunity at least 12 months prior to the end of manufacturing (except in cases where there is a direct form, fit and function replacement). It is ABB s intention to provide support for as long as there are significant customer needs after the "Manufacturing End" through field service, repair and by making replacement spares (new or refurbished modules) available. Your ABB automation system is designed for continuous evolution Always a path forward Protection of intellectual assets Underlying products are sustained by defined d lifecycle l phases Active until functional equivalent Defines minimum 10 years of support after removal from Active sale Lifecycle cle changes documented months in advance No other automation supplier has made as bold a commitment for all system products, to all system customers! October 11, 2012 Slide 16

17 Evolution Partnership with ABB Recipe for success October 11, 2012 Slide 17 Close collaboration to define the solution based on actual needs Most advanced safety platform providing reliability and availability to meet application requirements Single certified SIL-3 system (w/o redundancy) Minimum downtime Predefined modular solution Hot cut over capability Integrated control and safety systems stems (ICSS) Certified Safety Execution Centers 24 hours service centers Lifecycle Support (Sentinel ) Troll A Platform with System 800xA High Integrity

18 Evolution Partnership with ABB A long history in safety 30 years of experience in the design, implementation and installation of process safety systems Over xA High Integrity systems installed globally since 2005 Developed original integrated safety system in Safeguard Global installations in over 55 countries including largest platform on earth (Troll A) October 11, 2012 Slide 18

19 Condition of the Critical Safety System Infrastructure October 11, 2012 Slide 19

20 Process Safety Systems The installed base ARC estimates that the value of the installed base of process safety systems reaching the end of their useful life could be in the neighborhood of $8 billion worldwide. Replacing or migrating process safety systems, however, carries with it a unique set of concerns and considerations compared to process automation systems. Conforming to international safety standards, such as IEC 61511, means that end users must conduct a hazards and risk analysis in addition to allocating safety functions to protection ti layers. ARC INSIGHTS December October 11, 2012 Slide 20

21 Condition of the Installed Base Does your current safety system meet your needs? October 11, 2012 Slide 21 66% of Programmable Electronic Systems use in safety applications i were installed between 11 and 30 years ago Prior to IEC and IEC61511 / ISA 84 These are 1 st generation safety systems Many users have extended the lifespan beyond their suppliers obsolescence notice Grandfathered at ed relay based systems s still in place Spares and expertise becoming scarce Compatibility with current technology is questionable Failure rates are increasing

22 Condition of the Installed Base 1 st Generation safety systems Focused on remaining available for as long as possible (high MTBF) Responding in a pre- determined and safe manner (fail safe action) Compensated for limited diagnostics and dangerous failure modes with redundancy Were not designed according to the performance standards October 11, 2012 Slide 22

23 Condition of the Installed Base 2nd Generation safety systems 2 nd generation systems.. Were developed and/or certified in accordance with the IEC standards Provide additional software diagnostics to help identify latent faults However, they still Rely on redundancy for safety as well as availability Focus on identical paths and voting for Safety (hardware fault tolerance) Do not use diversity to eliminate common cause issues Some are certified to IEC61508 Edition 2, but not all October 11, 2012 Slide 23

24 2nd Generation Safety Systems Challenges of compliance to IEC Not all second generation systems can meet the new requirements Main Challenges: Traceability of requirements Changes to software developed prior to IEC standards is difficult Systematic capabilities Typically low Safe Failure Fraction (SFF) October 11, 2012 Slide 24 Lack of diverse technology

25 Generation High Integrity System 800xA HI is even better because it Designed according to IEC61508 with focus on all four SIL requirements Separated the two requirements for: Availability (MTBF) Safety integrity (i.e. HI meets SIL 3 without redundancy or voting) High degree of active diagnostics plus active discrepancy checking (between diverse paths) October 11, 2012 Slide 25 Systematic design including separate development teams in separate locations (Malmo, Vasteras) The fundamental design ensures that all detected faults are reported and either leave the controller operating in a degraded mode (but still safe) or initiate a safe action (shut down) Certified according to IEC61508 Edition 2

26 The Benefit of Next Generation Safety Systems October 11, 2012 Slide 26

27 Next Generation Safety Systems Benefits October 11, 2012 Slide 27 Next generation systems eliminate common cause failures and deliver significant benefits: Hardware & spare parts cost Less modules Current technology Cabinet space DIN rail mounted Less total hardware Maintainability Modern tools and programming Experienced workforce Safety standards Certified to current edition of standards Size Comparison: TMR vs. HI Processors (right) and I/O (left)

28 System 800xA High Integrity Diversity between Safety and Process systems Combining Control and Safety brings additional concerns and requirements: Common cause failures Diversity System 800xA addresses this with: Embedded diversity within the Safety System AC800M S880 I/O family Application Program execution Safety Engineering Environment Controller and I/O hardware diversity between Safety and Process Control Systems Firmware Development teams Operating systems Firewalls October 11, 2012 Slide 28

29 TRI to HI Evolution Program October 11, 2012 Slide 29

30 Evolution Planning Process Overview Evolution planning is an ongoing, collaborative process between ABB and our customers Our innovative approach consists of the following steps Discover (understand current status of systems and business) Plan (develop the desired end result the evolution plan) Propose (finalize the plan including products, processes and phased delivery proposal) Deliver (deliver the evolution project on time and on budget Kickoff Discover Plan Propose Deliver Maintain October 11, 2012 Slide 30

31 TRI to HI Evolution Program Background 1 st Generation Triple Modular Redundant (TMR) Systems It may be time to Evolve Many of the 1 st generation safety systems are Triple Modular Redundant (TMR) Many were installed during the first wave ( ) Possibly becoming difficult to find parts or support Costs to certify, expand or maintain are increasingi May need more information out of your system October 11, 2012 Slide 31

32 TRI to HI Evolution Program A typical plan October 11, 2012 Slide 32 Typical evolution plan will include: Design according to Safety Requirement Specification Replacing the obsolete safety hardware with certified modern controllers and I/O modules Modifying or replace cabinets Updating safety application code Configuring i the necessary interfaces to the DCS Documentation and Testing of hardware and software

33 TRI to HI Evolution Program Hardware replacement details Efficient hardware solutions: Reuse of existing termination panels (custom cabling solutions) Cost effective remote I/O solutions(upto20km) to Support for HART I/O maintenance functionality On-line firmware upgrades Hot swap module replacement Benefits: Footprint reduction Increased maintainability Reduced failure rates and downtime October 11, 2012 Slide 33

34 TRI to HI Evolution Program Application Code Options October 11, 2012 Slide 34 Code Conversion Using ABB or 3 rd party code conversion tool Still requires code tuning Existing code may lack documentation New Code based on SRS and HAZOP study 1 st G ti A li ti C d L dd L i Develop new code from design documents Leverages efficient engineering tool (Control Builder) and function diagram programming Uses certified safety libraries 1 st Generation Application Code Ladder Logic High Integrity Application Code Function Diagram

35 TRI to HI Evolution Program Control System Integration Options Integrated or Combined with System 800xA DCS Integrated with System 800xA DCS (same network etc.) Combined control & safety in the same controller Safety certified peer to peer communications Independent High Integrity Interfaced to any panel, HMI, DCS using OPC or Modbus TCP Read Only Flexible architecture including combined, integrated and interfaced to 3 rd party HMI or DCS October 11, 2012 Slide 35

36 TRI to HI Evolution Program Safety Execution Centers & Project Implementation ABB s SECs are certified by TÜV for Functional Safety Management System (FSMS) delivery and implementation of safety system projects. We have over 20 SECs (10 certified by TÜV), more than any other supplier in the industry. They are responsible for: Design and system integration according to our FSMS and the customer s safety requirement specification Providing TÜV certified and competent safety engineers / experts (over 250 globally) Offering safety consultancy and expert services October 11, 2012 Slide 36 These centers can be found in every region ABB serves, including: Argentina Norway Taiwan Brazil Denmark China Columbia Italy Korea United States France Thailand Canada Hungary Australia Mexico Egypt UK (3 offices) India Germany Singapore

37 TRI to HI Evolution Program Safety Sentinel October 11, 2012 Slide 37 Safety Sentinel is an extension of the Automation Sentinel Lifecycle Management program Exclusively for Triguard and Plantguard owners who are planning to evolve to HI Program includes: Maintain & Evolve level support Special price on High Integrity (HI) hardware Emergency spares sourcing support Dedicated technical support contact Up to and including the evolution project Will transition to standard support after evolution to HI Following Evolution, The user content will of this transition presentation is back to the standard Automation ABB Proprietary Sentinel and intended program for Internal Use

38 TRI to HI Evolution Program Additional Services Additional services are available to ensure your new safety system meets your current requirements HAZOPS Process Hazard Review (PHR) SIL Determination Certified Safety Execution Centers Certified engineers Project execution according to certified Functional Safety Management System Example of Process Hazard Review October 11, 2012 Slide 38

39 TRI to HI Evolution Program Project implementation support October 11, 2012 Slide 39 ABB can provide certified safety engineers to support during the design and implementation phase of the evolution project Safety Requirement Specification (SRS) development SIF requirements Functional safety requirements Proof test intervals and response time requirements FAT/SAT Support Hot Cutover On-line installation of hardware Phased hot-cutover to new systems Includes planning, cutover management Training Pemex Cadereyta Refinery. Upgrade of Triguard ESD to System 800xA High Integrity

40 Sales Tools Update

41 Safety Sales Tools Sales Kit October 11, 2012 Slide 41 Access from inside.abb.com Control Systems Internal Sales Support or Direct Link: index.htm

42 Safety Sales Tools Sales Kit October 11, 2012 Slide 42 New Sections coming for Independent High Integrity and TRI2HI Evolution Additional white papers and competitive information coming during October

43 Safety Sales Tools Sales Kit October 11, 2012 Slide 43 New Sections coming for Independent High Integrity and TRI2HI Evolution Additional white papers and competitive information coming during October

44 Safety Sales Tools Sales Kit New Materials October 11, 2012 Slide 44

45 Safety Sales Tools Updates to New Safety URL safety Updated Safety home page New TRI2HI page New Independent High Integrity page suggestions to Alicia DuBay October 11, 2012 Slide 45

46 Competition

47 Evaluation Criteria 1. Operational independence between process control system and safety system design 2. Methodology to achieve SIL 3, HFT, SFF, Systematic Capabilities 3. Strategies to avoid Common Cause Failures 4. Tight Integration 5. Competence of global execution centers 6. Time restrictions in degraded mode 7. Use of certified libraries 8. On-line Firmware upgrade, Audit Trail/Management of Change capabilities October 11, 2012 Slide Credentials of the independent assessor 10.Financial strength

48 Summary ABB Triconex Honeywell Hima Siemens Rockwell Emerson Yokogawa Operational Independence YES, TÜV Cert. Partial Yes Yes Not available Partial No Partial Diversity, Both HFT and HFT and HFT and Not HFT and HFT and Embedded Systematic Capabilities limited diagnostics limited diagnostics limited diagnostics available limited diagnostics limited diagnostics HFT and limited diagnostics Avoidance of CCF Integration without Data Mapping YES, TÜV Cert. YES, TÜV Cert. Partial Partial Yes Yes Partial Partial Yes No Yes No Yes No Yes Yes Safety Execution YES, 24 Few, 3 No Yes, 12 Not No Few, 4 Few, 7 Centers available Time Restrictions No No Yes Yes No Yes Yes Yes Certified Librariesi On line FW Upgrade Certification agency Yes No No Yes No No No No Yes No No No No No No No TÜV SUD TÜV Rheinland TÜV Rheinland TÜV Rheinland TÜV SUD TÜV Rheinland TÜV Nord TÜV Rheinland Global Presence Yes No No No No No No No in Safety October 11, 2012 Slide 48

49 Questions

50 October 11, 2012 Slide 50