Trusted fault tolerant technology

Transcription

1 Trusted fault tolerant technology

2 The highest availability for your safety solution Experts in safety The prevention of one unplanned nuisance trip or one system failure can save your operation millions of dollars in lost revenues, equipment replacement, environmental damage and protect your most valuable asset; the lives of your people. This is why you should be talking to ICS Triplex for all of your safety critical applications. For over 35 years, ICS Triplex has provided safe reliable solutions to protect people, assets and the environment. With a large installed base of critical control systems we are the experts in safety. Trusted Trusted, the ICS Triplex flagship product, has the smallest footprint in the industry. It uses RunSafe fault-tolerant control to virtually eliminate spurious trips and offers the highest availability and lowest cost of ownership of any SIL3 rated safety system available. Save on cost ICS Triplex have taken great care to make the Trusted product easy to use and easy to integrate into wider control schemes. So easy in fact, that by using Trusted, you can now have the true fault tolerance of TMR at the same or lower overall cost than redundant PLCs. And that s not just purchase price; because Trusted TMR is packaged to make it easy to use, life time cost of ownership is significantly lower than alternative schemes. Investing in innovation ICS Triplex operates one of the most proactive R&D departments in the automation industry today. With a team of over 40 people worldwide and a large proportion of the Company's turnover allocated to research and development projects yearly, ICS Triplex invests in the resources to make a difference. safe, simple, reliable 2

3 Safety standards The standards IEC61508 and define the performance and design parameters for safety instrumented systems to cater for a wide range of risks called Safety Integrity Levels (SIL). The three basic parameters defined are: Probability of Failure on Demand (PFD), Safe Failure Fraction (SFF) and minimum fault tolerance requirements. It is relatively easy to improve a system s safety performance, but, this can result in plant uptime being compromised. So what about safety? A safety PLC is specifically designed to ensure that it does not fail and in the case that this cannot be avoided, it fails in a safe way. To ensure a fail safe status at any cost could lead to regular periods of process downtime which itself can be a hazard to personnel and the process plant. At ICS Triplex we design systems with zero downtime as a main objective. Trusted is RunSafe technology, designed for the real world where fixing a fault can rarely be done immediately. Although designed to exceed the highest safety requirements, it also ensures that whenever possible the system will continue to control the process even with multiple system faults present. Removing human error In order to further reduce human errors, Trusted is designed to be as simple as possible. With fault tolerance designed as a basic feature of the system, the operation is straightforward minimising the opportunities for error. From the pure TMR design to the comprehensive diagnostics of field signals, Trusted helps the user to maintain the system in a safe way. The Trusted product range includes all the integration materials required to construct a working system. Using these carefully designed and tested materials removes the risk of time limited project engineers building in later problems. Using Trusted for all Safety Integrity Levels makes sense. A consistent fault tolerant architecture for all safety needs minimises the opportunity for confusion as well as ensuring the minimum contribution to PFD (Probability of Failure on Demand). Certification Certified by TÜV as suitable for AK6 applications and NFPA 72, 85, 86, as well as IEC61508 SIL1 3, Trusted uses RunSafe fault tolerant control (First fault: fault tolerant, Second Fault: fault tolerant, Third fault: failsafe) to virtually eliminate spurious trips. In this way ICS Triplex delivers the highest availability and lowest cost of ownership of any SIL3 rated safety system currently available. Trusted is UL listed for use in Class 1 Div 2 Groups A, B, C and D and EExnAL IIC T4: DEMKO 05 ATEX X. As well as conforms to UL508 and certified to CSA C22.2 NO 14 and CSA C22.2 NO

4 no unplanned shutdowns Fault tolerance for every process ICS Triplex technology and expertise is used in critical processes throughout the world to ensure safety of personnel, the plant and the environment. ICS Triplex solutions ensure maximum availability and reliability for a host of applications including: Emergency ShutDown (ESD) Fire and Gas detection (F&G) Burner Management Systems (BMS) TurboMachinery Control (TMC) The TMR technology of Trusted lends itself to all aspects of a combustion process. From the prevention of start-up should the appropriate criteria not be met, to the shutdown of the process as soon as the conditions become inappropriate, ICS Triplex can provide safety that is fault tolerant. Turbomachinery control The Trusted turbomachinery controller provides superior compressor and turbine control at an unmatched value. No other automation solution combines advanced control, operator interface and configuration in such a value based package. Emergency shutdown TMR safety systems provide the highest SIL level of safety for processes requiring emergency shutdown. The high availability of Trusted makes it an ideal solution for those working to ensure safety for the environment and their personnel, as well as the economic protection of their investment. A Trusted ESD system can be used for: Safety critical control Compressor station control High Integrity Pressure Protection Systems (HIPPS) Fire and gas Whether required for a petrochemical processing unit or a floating production vessel, ICS Triplex can provide you with the best safety solution for F&G detection and protection. Burner management ICS Triplex can ensure the safe operation of boilers, multi-burner process-fired heater units and simple boilers by using Trusted as a BMS. 4

5 Why Trusted? TMR and HIFT, the no compromise solution. Trusted technology is designed to provide maximum safety and availability in all circumstances. Triple Modular Redundancy (TMR) uses majority voting to identify a source of failure. All random hardware failures cause one slice of the TMR system to react differently to the others. This discrepancy will be captured and reported by the voting system. With TMR you make the right decision every time but only when you have to. The hardware voting (HIFT) technology unique to ICS Triplex technologies has major benefits including: The highest test coverage of potential faults Tolerance to multiple failures No time repair restrictions Accurate fault identification Reduced operating system size and complexity The alternatives As well as other TMR based solutions that use less stable software to perform majority voting, alternative safety system technologies rely on diagnostics to achieve safety. Dual/quad redundancy is then employed to reduce the likelihood of each diagnostic activity causing a trip. All dual and dual/quad mixed architectures compare channel activity and use the diagnostics to decide, which one is right and which is wrong. If a correct decision cannot be guaranteed then the system must shutdown to a safe state. TMR systems offer the best overall performance compared to any other technology. They offer the fewest nuisance trips in combination with the highest safety performance, as well as being suitable for use in the highest risk levels defined by industry standards. The Trusted system is the simplest, safest and most reliable TMR system on the market. Every feature of Trusted technology has been designed to benefit your operation throughout its long life. In short, distributed HIFT technology and TMR offer the user a system with key capabilities: Always a SIL3 component of your system and always fault tolerant Stable, predictable operation High capacity and high speed The simplest to use and maintain 5

6 the smallestfootprint Trusted features and benefits Trusted controller Trusted is highly compact, 240 fault tolerant TMR I/O with Modbus communications in a single 6U chassis. At the heart of each Trusted system is the controller chassis housing the TMR processor, its companion slot for bumpless change out to a spare and 8 interface slots for I/O modules, communications modules or interface modules to expanders. Trusted expander Up to ten I/O expanders, each housing up to 12 I/O modules may be located up to 10km distant, connected by separate 250Mbit high speed triplicated fibre optic links to the controller. I/O modules A wide range of dedicated modules for both analogue and digital, plus a unique I/O module that allows you to mix signal types on the same module gives maximum flexibility to closely match the application requirements. All modules have full stuck on stuck off testing, configurable line monitoring and indication LEDs per channel. I/O configuration is easily set in software with the loop parameters set by link configuration on the termination assembly. IEC configuration tools The Trusted IEC61131 Toolset allows you to define up to 250 individual programs using any of the 5 specified languages (LD, FBD, ST, SFC and IL) in each project. Offline simulation, online de-bug and graphical interface provide simple and appropriate tools for configuration, verification and maintenance of the application logic. Power supplies Trusted can be powered directly from a single or dual conditioned 24Vdc supply or from ac sources using the Trusted modular power system to provide redundant power feeds. Supply configuration can be either 100% redundant or n+1. 6

7 in safety Integration hardware A comprehensive range of I/O termination panels, power distribution units, pre-wired cable harnesses and many other integration aids make building and integrating a Trusted system quick and easy. Connectivity Trusted communications use Ethernet and TCP/IP for interfacing with PC based graphics, PLCs, host DCS as well as the TÜV certified peer-to-peer link. Commercially available Ethernet hardware and software tools are utilised to build fault tolerant Ethernet LANs. Trusted also uses OPC (Object linking and embedding for Process Control) to give drag and drop connectivity to any OPC client with network redundancy managed by the OPC server software. Open but safe Using Ethernet, Trusted can integrate with other process management products. OPC allows seamless integration with a host system. The Trusted OPC implementation includes the data acquisition plus alarms and event functions. This ensures that all locally time stamped data is transferred to the host system, maintaining the unique 1ms SOE resolution. Remote diagnostics Using the Internet, a Trusted system can be configured and monitored from anywhere in the world provided local security permission is given. Signature analysis diagnostics Predictive maintenance diagnostics provide signature analysis of end device as well as environmental conditions of the hardware, alerting the operator to problems before they happen. Scan time optimisation I/O module scanning is user configurable to suit the dynamics of the process measurement. Scan time optimisation ensures the maximum performance from your Trusted system. 1ms time event stamps True 1ms sequences of events (SOE) resolution (regardless of system size), for each alarm threshold, analogue or digital, input or output point, configured at the module to give the operator the most accurate resolution for process and system level alarms. Sitewide synchronised time All Trusted systems can be synchronised to any IRIG-B time source for sitewide synchronisation of all events to a few milliseconds. Firewall protection The Trusted IEC61131 Toolset makes use of the Firewall protection designed into the operating system to guarantee that safety-related application tasks are isolated from non-critical tasks. 7

8 A wide range of specialist modules The TMR structure of Trusted was developed to make enhancing its potential possible. ICS Triplex R&D is constantly working towards increasing the already wide capabilities and unique features of Trusted. With an increasing number of specialised modules, Trusted is a versatile product. Its ability to adapt to specialist requirements, without compromising its standard offering, provides unmatched flexibility, making it a leading edge product in safety and control. Users appreciate the space saving and very small footprint of the Trusted chassis and the flexible range of input/output modules that make it possible to tailor each unit very closely to the application for maximum cost effectiveness. The Valve Test module Trusted offers a solution that checks the valve operation by controlling a partial movement, guaranteed to not be more than a predetermined amount. By timing the valve movement to a 1ms accuracy and restoring the output to normal, it achieves the test objectives without process interruption. This partial stroke testing of critical valves is a crucial part of meeting the latest process safety standards. The Trusted system integrates automatic valve testing inside a TMR, TÜV approved (SIL3/RC6) architecture for maximum safety and availability. With this package you are able to increase the system s SIL at almost no additional cost by periodically testing the valve and actuator subsystem without closing the valve, in other words without shutting down the process. The Zone Interface module The Trusted Zone Interface significantly reduces the complexity of a F&G system by integrating all functions in a single module. It can be used in combination with any other Trusted hardware. The 40-channel Zone Interface provides fault tolerant monitoring of any 4-20mA gas detector, in addition to any low voltage digital signal, with line monitoring. These include flame, smoke or heat detectors and manual alarm callpoints. The same module provides outputs for the control and alarm of hazards as well as the calibration of detectors. The Speed Monitor module Trusted offers an unmatched solution for the protection of gas/steam turbine acceleration and overspeed. The module provides autonomous overspeed protection for up to three rotating machines. Each overspeed trip has three independent, fault-tolerant speed inputs and a faulttolerant digital output. Speed inputs have a wide, dynamic range of 0.1Hz to 30KHz. Like all other Trusted module I/Os, it provides sequence of event reporting with 1ms resolution. Unique solutions Further to the application driven developments already available, ICS Triplex is able to develop technologies for unique applications. Our portfolio includes a number of customer specific innovative developments that have been used both in research and industry. technology driven, customer led 8

9 Intelligent field interfacing Triplicated Host Interface Unit (HIU) TMR processors HIFT bus interface MT operating system 1ms time stamping Triplicated Field Interface Unit (FIU) A/D conversion Field interface testing Line monitoring Threshold determination Over current detection Front Panel Interface (FPI) Module/slice health Active/standby status Educated status Per channel field status Per channel health Module release levers Field Termination Board (FTB) Field power and signal connection Signal conditioning Field isolation PCBs are monitored for temperature and humidity. Internal measurements of voltage, current and critical component status provide detailed remote diagnostics of system condition.. The composite design of Trusted field interfaces reduces PCB variety. All TMR interface modules use an identical HIU and FPI board. FIU and FTB are designed to meet the needs of the interface module type. All electronics and mechanical components are protected by the moulded plastic housing. 9

10 Protecting people, investments and the environment 10

11 Trusted, making safety right for you Training Trusted architecture and design lend themselves to easy maintenance. ICS Triplex offers training courses that range from general overviews, giving the user an understanding of the capabilities of the product, to longer courses that include programming as well as focused bespoke packages that are project specific. ICS Triplex also offers engineering services through the Regional Technical Services (RTS) team. RTS RTS is designed to ensure that all ICS Triplex products attain the highest possible availability and reliability wherever their location. With over 35 years of experience, RTS engineers are trained to deliver services of the highest standard including: Site implementation Systems modifications Upgrades Training Maintenance contracts Regional capabilities on a global scale With offices located in all key industry areas, RTS offers 24/7 call out support, telephone support and emergency contact. A unique service RTS engineers specialise in safety systems RTS engineers are specialists in RunSafe technologies RTS is able to provide field device implementation expertise RTS will ensure that you maintain safety standard compliance throughout the life of your process 11

12 ICS Triplex offers safety and control solutions that help to protect people, the plant and the environment while improving productivity and profitability. Together, ICS Triplex and Rockwell Automation bring the combined expertise of both companies to customers worldwide, creating one of the most comprehensive automation solutions available today.