, CFSE, Senior Manager, ABB Taiwan;, 2011/9/2 Functional Safety September 5, 2011 Slide 1
(Ken Meng) Computer Engineering /DCS/ 8 2 ABB Ltd DCS 12 ( 3 9 ) CFSE (Certified Functional Safety Expert) E-mail: ken.meng@tw.abb.com Phone: (02) 2299 3299 ext. 326 Mobile: 0933 861 052
Disasters that must not be repeated! September 5, 2011 Slide 3
(Risk) impossible! IEC61508 practicable! (Functional Safety) September 5, 2011 Slide 4
1. 2. 3. September 5, 2011 Slide 5
(Functional Safety)? September 5, 2011 Slide 6
Why Functional Safety?!???? (PFD) IEC61508 & IEC61511 / / September 5, 2011 Slide 7
? 1. HAZOP 2. 3. 4. MTBF & SFF 5. 6. September 5, 2011 Slide 8
Functional Safety Risk: Functional Safety: IEC61508 / 61511: Functional Safety Lifecycle: SLC: Safety Life Cycle, Failure Rate: PFD: Probability of Failure on Demand, SIL: Safety Integrity Level, BPCS: Basic Process Control System, SIS: Safety Instrumented System, Proof Testing: TUV: Availability & Reliability: & September 5, 2011 Slide 9
HSE Study of Accident Causes: involving Control Systems Operation & Maintenance 14% Installation & Commissioning 6% Specifications 44% Design & Implementation 15% ABB Automation Technologies - 10 September 5, 2011 Slide 10 Changes after Commissioning 21% HSE: Health and Safety Executive
Shell SIS SLC Refinery: Hydrogen Manufacturing Unit 47% No Change 49% Over Engineered ABB Automation Technologies - 11 September 5, 2011 Slide 11 Shell: SLC: Safety Life Cycle 4% Under Engineered
NAM SIS SLC Total of 5319 loops are considered at 7 different plants 57% No Change 37% Over Engineered ABB Automation Technologies - 12 September 5, 2011 Slide 12 NAM: SLC: Safety Life Cycle 6% Under Engineered
Functional Safety Applications Emergency Shutdown Systems (ESD) Process Shutdown Systems (PSD) Fire & Gas Protection/Detection (F&G) Critical Control Boiler/Burner Management High Integrity Pressure Protection Systems (HIPPS) Pipeline Protection Systems (PPS) Industries Oil & Gas companies Refineries Petrochemicals companies Pulp &paper Marine Metals Machinery Utility Fossil/Nuclear Fuels September 5, 2011 Slide 13
1995 2005 USA UK Germany International API RP14C 1974 HSE PES DIN VDE 0801 DIN VDE 19250 1987 ISO 10418 1989 OHSA CFR 1910.119 1995 IEC SC 65 IEC 61508 Draft 1991 1992 1993 ISA ds84.01 1995 Draft ANSI/ISA S84.01 1999 IEC 61511 1996 2003 2004 ANSI/ISA S84.00.01 (IEC 61511 Mod) September 5, 2011 Slide 14
IEC 61508 Safety Lifecycle Phases and Responsibilities 1 Concept Analysis Phase (End User / Consultant) 2 3 4 5 Overall Scope Definition Hazard & Risk Analysis Overall Safety Requirements Safety Requirements Allocation 6 Overall 7 Overall 8 Operation & Maintenance Planning Overall Planning Validation Planning Overall Installation & Commissioning Planning 9 Safety-related systems: E/E/PES Realization 10 Safety-related systems: Other Technology Realization 11 External Risk Reduction Facilities Realization Realization Phase (Vendor /Contractor/End-User) 12 13 Overall Installation & Commissioning Overall Safety Validation Back to appropriate Overall Safety Lifecycle phase 14 Overall Operation & Maintenance 15 Overall Modification & Retrofit Operation Phase (End User / Contractor) 16 Decommissioning September 5, 2011 Slide 15
IEC 61511 Safety Lifecycle Hazard and risk analysis Management of functional safety Safety life cycle model Competency Functional safety assessment Planning Configuration management Verification Validation Standard content structured according to life cycle model Management of functional safety and functional safety assessment Safety lifecycle structure and planning S1 S2 S3 S4 S5 Allocation of safety function Safety requirement specification Design and engineering of SIS Installation, commissioning and validation Operation and maintenance Modification Design and development of other means of risk reduction Verification Decommissioning September 5, 2011 Slide 16
What is Risk? What can happen? How often? What is the consequence? Risk = Consequence * Frequency High Calculated Process Risk Process Design Risk SIL-1 SIL-2 SIL-3 Other Risk Reduction (Alarming, Exception Procedures, ) Safety Instrumented System (SIL-1, SIL-2, SIL-3, ) Tolerable Level of Risk (Defined by user per application) 0 Risk Reduction is the Highest Priority ALARP (As Low As Reasonable Practicable) September 5, 2011 Slide 17
Probability of Failure on Demand (PFD) PFD depends on failure rate ( ), failure mode and test interval Failure rate is divided into failures that can cause a false trip versus those that failure on demand An untested device s PFD gets larger as the operational time interval increases For devices subject to periodic inspection and test the average PFD can be used PFD avg ~ ( t)/2 September 5, 2011 Slide 18
Safety Integrity Levels SIL Safety Integrity Level SIL 4 SIL 3 SIL 2 SIL 1 PFD Probability of Failure on Demand (Low Demand mode of operation) >=10-5 to <10-4 >=10-4 to <10-3 >=10-3 to <10-2 >=10-2 to <10-1 >= 0.01 to < 0.1 RRF Risk Reduction Factor 100000 to 10000 10000 to 1000 1000 to 100 100 to 10 PFD Probability of Failure on Demand (Probability of Dangerous failure). September 5, 2011 Slide 19
Control & Protection Functional View Example of safety design The protection in 2 levels: Primary Secondary Functionally different types Protection System (Secondary) Process Control System Protection System (Primary) PSV PT PSHH LSHL V-101 ESD LT
Physical vs. Logical separation Physical vs. Logical Safety System Combined Controller Safety Functions Control System Control Functions C S C S S C S C Physical Separation Logical Separation Note: Logical separation can be provided by an internal firewall to provide protection from unintended, spurious, or unauthorized access from other controllers, applications, and operator/engineering stations September 5, 2011 Slide 21
Example 1 Calculations of function SIL2 Sensors Logic Solver Actuators Component No. of components Total PFD mnt per 10 6 hrs Logic 1 12 0.1 0.44 10-3 Transmitter 1 6 1.6 3.50 10-3 ESV / XV 1 6 1.3 2.85 10-3 Solenoid / pilot 1 6 1.4 3.07 10-3 Total Function - 0.00986 - Fault Rate Test Interval, in month PFD Probability of Failure on Demand
Example 2 SIL Calculations I I I I I Flow Transmitter 2oo3 Pressure Transmitter 1oo2 Temp. Switch 1oo2 Logic Solver September 5, 2011 Slide 23 Level Switch 1oo2 1oo2
Example 2 SIL Calculations Results Sensor Voting MTTF DU PFD avg Equation Flow 2oo3 40 6.25 x E-4 PFD (2oo3)avg = ( DU ) 2 x TI 2 Pressure 1oo2 50 1.33 x E-4 Temperature 1oo2 15 1.48 x E-3 Level 1oo2 25 5.33 x E-4 PFD (1002)avg = [ ( DU ) 2 x TI 2 ] / 3 Total 2.77 x E-3 Final Element Voting MTTF DU PFD avg Equation Solenoid Valve 50 Block Valve 50 Note: = (Sov) + (Block) SOV + Valve 1oo2 5.33 x E-4 PFD (1002)avg = [ ( DU ) 2 x TI 2 ] / 3 Logic Solver PFD avg = 5 x E-3 (provided by Mfr.) PFD SIF = PFD Sensor + PFD Logic Solver + PFD Final Element = 2.77 x E-3 + 5 x E-3 + 5.33 x E-4 Assume: Test Interval = 1 yr September 5, 2011 Slide 24 = 8.3 x E-3 Meet the Requirement of SIL-2 System
From Relay Logic to Integrated SIS
SIS and BPCS Integration Level:
SIS and BPCS Integration Level:
SIS and BPCS Integration Level:
ABB Safety System Offerings AC800M HI: 1 oo (1oo2D) Released at 2008 4 cpu run on parallel SIL 1-3 AC800M HI Plantguard (TMR, 2oo3) Released 2004 3-2-0 & 3-2-3-2-0 degradation SIL 1-3 Plantguard September 5, 2011 Slide 29
800xA High Integrity Redundant / Quad Configuration SM811 BC810 PM865 TB 840 Redundant I/O Optical Modulebus CEX bus RCU Link
800xA HI ABB Safety Certificates Product Safety Certificate Development Department Safety Certificate Safety Manual TÜV Product Service, the foremost independent certification agency in the business, has certified all product components on the 800xA Safety offering September 5, 2011 Slide 31
Safety Certificate for Persons CFSE (Certified Functional Safety Expert) CFSE: Certified Functional Safety Expert 10 years of safety related + Exam + Case Study CFSP: Certified Functional Safety Professional 2 years of safety related + Exam Certified by exida Taiwan: CFSE: 7; CFSP: 9 TUV FS (Functional Safety Program) TUV FS Expert 8 years + Document assessment TUV FS Engineer 3 years + Training course Certified by TUV Rheinland Taiwan: Expert: 0; Engineer >20
ABB 800xA High Integrity System Architecture MES and Business Systems Knowledge Portals as Thin Clients Remote Operator and Engineering Clients 3rd party PLC s ECS, ISA-95, OPC Serial, OPC.. Extended Operator Workplace Maintenance Operation Operation Engineering System Servers Process Electrification LV & MV - Switchgears - Smart MCC s - Frequency converters - Multi-drive Ethernet Control Network Process Automation Local Panels - Boiler Protection - Burner Management Safety Power Distribution Power Management - Network control & protection - Load Shedding Process Instrumentation September 5, 2011 Slide 33 TCP/IP IEC61850
Situation System 800xA TodayExtended Automation System Islands The Power of Automation of Integration System 800xA PLC PLC, SCADA PLC, Panel PLC PLC, SCADA PLC, Scada PLC, Panel PLC PLC DCS 3 PLC DCS 3 PLC, SCADA PLC DCS 2 DCS 1 PLC PLC, Scada DCS 2 One rich harmonized user interface including all control systems PLC, SCADA One integration DCS point 1for all related applications PLC ABB / BU PIP / OCS 3BSE064772 en B September 5, 2011 Slide 34
System 800xA System 800xA Over 6000 systems sold since launch in January 2004 Over 24,000 operator stations Over 30,000 AC800M controllers Over 20 Million I/O points Systems sold in a wide range of industries and geographies Safety HI Controllers Over 1,800 HI controllers since launch in January 2005 ABB / BU PIP / OCS 3BSE064772 en B September 5, 2011 Slide 35
Plant overview and information in real time Promotes collaboration and optimization Smart Client Desktops Plant Network/ Internet Smart Client Server Firewall ABB / BU PIP / OCS 3BSE064772 en B September 5, 2011 Slide 36
800xA Improved visualization for the operators - complete overview of the recovery boiler Common engineering for AC 800m and 800xA High Integrity Increased flexibility and simplified maintenance Easier to maintain engineering competence Increasing demands from authorities will put demands on further changes in safety systems Korsnäs has ordered 800xA High Integrity for the second recovery boiler as well! ABB / BU PIP / OCS 3BSE064772 en B September 5, 2011 Slide 37
800xA ABB / BU PIP / OCS 3BSE064772 en B September 5, 2011 Slide 38
800xA Maintain what needs to be maintained (predictive maintenance) Increased opportunities for an effective maintenance plan ABB / BU PIP / OCS 3BSE064772 en B September 5, 2011 Slide 39
Electrical Integration ( ) Electrical Integration is the integration of Process Automation and Power Automation into one system Process Automation Process Instrumentation Measurement and control of pressure, temperature, flow Process Electrification Monitoring and control of motors, pumps, fans Power Automation Substation Automation Protection, monitoring and control of generators, transformers, switchgear Power Management Advanced control of power distribution September 5, 2011 Slide 40
& Organizational barriers among process and power department Device specific solutions for integration into DCS A lot of hardwiring needed Lack of information from electrical devices Many protocols, lack of global standard Separate system for power automation September 5, 2011 Slide 41
System 800xA Full Plant Integration with System 800xA Electrical Integration Based on Open Standards Complete Portfolio from ABB September 5, 2011 Slide 42
System 800xA Common engineering Common operations Common system architecture Common information management Common Centralized asset Historian management and Data Archiving September 5, 2011 Slide 43
Customer Benefits Improved Operator Effectiveness Process group Power group September 5, 2011 Slide 44
Integrated Process and Power Automation Summary Reduced Investment Costs Improved Operator Effectiveness Reduced Maintenance Costs Increased Plant Availability Reduced Energy Costs September 5, 2011 Slide 45
September 5, 2011 Slide 46
Outstanding overview All information is synchronized for faster operator interaction Personalized workplaces for safe and efficient operation Efficient tools and navigation features for faster operator actions September 5, 2011 Slide 47
ABB Instrumentation SIL compliant or conforming instrumentation for use in safety applications SIL rated instrumentation completes the safety instrumented function/solution HART sensors for pass-through connection into S800 AI880 module for use in non-safety critical functions and asset optimization. Declaration of Conformance vs. TUV certification September 5, 2011 Slide 48
ABB Total Safety Offering SIS Systems TUV Certified Flexible and Scalable System 800xA SafeGuard PlantGuard Field Instrumentation SIL rated Instrumentation Valves Safety Requirements Proof Testing Support TRAMs Proof test period Maintenance Lifecycle Support Alarm Management Benchmarking EEMUA 191 Training Support September 5, 2011 Slide 49 SIL Determination Analysis TRAC Training Mentoring Design and Installation Maintain Safety Performance Full Scope Supplier Installed Systems Review SIL assessment Benchmarking IEC 61508/IEC 61511 Compliance Compliance Management
: (12 DRAM) R1 FMCS Operator Stations x 4 (Dual screens) 2oo3 Redundant Aspect Servers (AS) Dual Domain Controller (DC) Dual Info. Management Server (IM) Office Network for Firewall, EDMS, and Info-Center PC To 12D & Office network Firewall VESDA, PA, FA CCTV, Access OPC (by Others) Red. CS ERC OS x 2 Core Switch Redundant Client/Server Network (Ethernet) Edge Switch Controllers & I/Os not shown! Engineering Station (ES) LED Ticker Anti-virus Server AO Server File backup Server Fiber Optics (Star) Clean Room HVAC WTS GAS Chemical OS x 3 OS x 1 OS x 2 OS x 3 OS x 1 Red. CS Red. CS Red. CS Red. CS x 2 Red. CS Edge Switch Controllers & I/Os are not in FMCS scope. Edge Switch Profibus-DP Red. AC800HI Controllers & Safety I/O Edge Switch Controllers & I/Os not shown! PLC-1 PLC-2 PLC-n Edge Switch Profibus-DP Edge Switch Controllers & I/Os not shown! UPW/PCW/WWT September 5, 2011 Slide 50
September 5, 2011 Slide 51