Daniele Corali, ABB SpA – Process Automation Division ... · 800xA High Integrity – ABB Safety...

© ABB Group June 4, 2012 | Slide 1

Riduzione del rischio con sistemi di automazione di sicurezza

Daniele Corali, ABB SpA – Process Automation Division

© ABB Group Febbraio 2012 | Slide 2

Leader globale nelle tecnologie per l’energia e l’automazioneLeader di mercato nei principali business

135.000 dipendenti in oltre 100 paesi

38 miliardi di dollari in ricavi (2011)

Nata nel 1988 dalla fusione di società di ingegneria svedesi e svizzere

Gruppi precursori fondati nel 1883 e nel 1891

Gruppo quotato in borsa con azionariato diffuso e sede principale in Svizzera


Power and productivity for a better worldLa nostra visione

ABB, uno dei principali gruppi di ingegneria a livello mondiale, aiuta i suoi clienti a utilizzare l’energia elettrica con efficienza, aumentare la produttività industriale e ridurre l’impatto ambientale in maniera sostenibile.


La nostra strutturaCinque divisioni globali

Power Products

Power Systems

Discrete Automation and Motion

ProcessAutomation

8,4 miliardi di dollari27.500

dipendenti


dipendenti

(Ricavi 2011)

Low Voltage Products

5 miliardi di dollari21.000

dipendenti

10,3 miliardi di dollari 35.000

dipendenti


dipendenti

Apparecchiature elettriche, automazione, sistemi di controllo e strumentazione per la generazione di energia e i processi industriali

Trasmissione di energia

Soluzioni per la distribuzione

Prodotti di bassa tensione

Motori e azionamenti

Sistemi per edifici intelligenti

Robot e sistemi robotizzati

Servizi per aumentare la produttività e affidabilità

Il portafoglio ABB comprende:


Energia e automazione sono ovunque intorno a noi Troverai la tecnologia ABB…

in orbita attorno alla terra o al lavoro in profondità,

attraverso gli oceani e sul fondo del mare,

nei campi in cui crescono i nostri raccolti e nei processi di confezionamento del cibo,

nei treni su cui viaggiamo e negli impianti che trattano la nostra acqua,

nelle centrali dove si genera la nostra energia e ovunque nelle nostre case.


Un contributo allo sviluppo tecnologico grazie all’innovazione All’avanguardia dal 1883Fondatori

1900

Robot industriale

Turbosoffiante

HVDC

Altissima tensione

Interruttore isolato in gas

Azionamenti motore a velocità variabile Sistemi di controllo esteso

Turbina a vapore

1920 1930 1940

Propulsione elettrica

1990 2000

19601970

Turbina a gas

1950

Convertitore di frequenza

1980

© ABB Group 4 giugno 2012 | Slide 7

Riduzione del rischio con sistemi di automazione di sicurezza


Contents

ABB in Safety Market

800xA High Integrity System Overview

Certificates

AC800M High Integrity

Engineering

Operation

Maintenance

Security

PLUTOSafety PLC

ABB in Safety MarketLarge portfolio

Safety 2600TPressure Transmitter

System 800xA High Integrity

DTM

EDP300Position Master


Safety 2600T Measurements

Pressure

Diff. Pressure

Level

Interface level

Volume

Flow

Density

ABB in Safety MarketInstrumentation

PRESSURE DETECTIONELEMENT 2 LINEARIZATION &

COMPENSATION

Standard architecture

Redundancy Diagnostic

OUTPUT2

VOTING

COMPARATOR

VERIFYSUPPLY

COMPARATOR

WATCHDOG

4 20 mA SAFE OUTPUT

CLOCK2

A / DVERIFYOUTPUT

FAILSAFE

ENABLE

4 20 mA

OUTPUT1

HART

4 20 mA

PRESSUREDETECTIONELEMENT 1

Temperature sensor

LINEARIZATION &COMPENSATION

VALIDATIOND / A

CLOCK1


Machine SafetyPluto Safety PLC

“All-master system and the best of new and traditional solutions”


Machine Safety9 new product families

Training & Advice

Practical application of standards and regulations, along with CE-Labelling.

Pluto Safety PLC

A unique All-Master safety PLC fordynamic and static safety circuits.

Vital safety system

Dynamic safety circuit for several sensors in accordance with the highest safety category.

Tina adapter units

Transformation of static signals to dynamicsafety signals.

Safety relays

The market’s most flexible safety relays for different protection purposes and categories.

Stopping time & machine diagnosis

Used to stop time measurement, annualmaintenance and for troubleshootingmachinery.

Light curtain/light beam/scanner

Complete range of light beams, light curtainsand scanners.

Sensors/Switches/Locks

Dynamic non-contact sensors, key switchesand solenoid switches.

Control devices

Ergonomic three-position control units,two-handed control units and foot pedals.

Emergency stop devices

Emergency stop devices for dynamic and static safety circuits.

Crush protectio/Safety mats

Sensitive edges, bumpers and safety.

Fencing systems/safeCAD/Roller doors

A stable and flexible fencing system easy to install.


Machine SafetySolution approach



Contents



Certificates


Engineering

Operation

Maintenance

Security


800xA High Integrity System Overview Separate

Workplace

Remote Clients

System Servers

Process Automation

EngineeringWorkplace

Direct communication link

Module Bus

Safety

WorkplaceEngineering

System Servers

Control Network


800xA High Integrity System OverviewIntegrated

Workplace

Remote Clients

Process Automation


Module Bus

Safety


System Servers

Control Network


800xA High Integrity System Overview Combined

Workplace

Remote Clients

Process Automation


Module Bus

Safety


System Servers

Control Network

Process Automation and Safety

Same engineering tools Same human systems interfaceSame Alarm Management and SOESame historian Same audit trailSame asset and device managementSame or shared instrumentationSeparate control applications for BPCS and SIS

Embedded environment reduces duality and associated lifecycle costs of maintaining separate systems (i.e. less spare parts, common training, etc.)

800xA High Integrity System OverviewSimplified operation and maintenance



Contents



Certificates


Engineering

Operation

Maintenance

Security


Certificates 800xA High Integrity – ABB Safety Certificates

TÜV Product Service, the foremost independent certification agency in the business, has certified all product components on the 800xA Safety offering

Product Safety Certificate

Development Department Safety

Certificate

Safety Manual


The FSMS consists of the Safety Team and of some other support functions / processes.

Company processes are defined and described in the QM; Processes associated with safety related issues are:

Front End,

Project Management,

Hw / Sw ProductionDocumentation and Testing,

Commissioning,

Service,

Supply Chain Management,

Human Resources.

CertificatesFSMS Functions

Certificates



Contents



Certificates


Engineering

Operation

Maintenance

Security


AC800M High IntegritySingle Configuration

SM811 PM865 Single I/O AI8880, DI880 and DO880TB840


AC800M High Integrity Redundant Controller Configuration

The 800xA High Integrity system can be configured in a redundant controller configuration

800xA High Integrity offers availability figures comparable to or better than typical TMR systems

Availability up to 99.9999%

Redundancy and switch-over to stand-by unit allow continuous operation without time restriction upon failure of one of the redundant modules

4 CPUs


S800 High Integrity I/OI/O Modules

DI 880 - 16 Channels

AI880A - 8 Channels HART pass through functionality

DO880 - 16 Channels

Features

Single and Redundant configuration

Hot Insertion and Hot Swap in redundant configuration

G3 Coating

Embedded Diversity


AC800M High Integrity Communication Interfaces

Communication through mentioned modules certified “interference free”

I.e. can be used in a safety system, but not for a safety critical function

All certified interference free modules listed in the ABB Safety Manual


AC800M High Integrity Peer To Peer Communication

Workplace

Remote Clients


Module Bus

Safety


System Servers

Control Network

Module Bus

Safety

MMSReadHI

Control Modules

Logic_B

Program

MMSDefHI

Control Modules

Logic_B

Program

Data type check added in both

Any simple data type can be communicated

AC800M High Integrity“Stand Alone” safety offering

Safety Logic SolverTUV Certified (SIL 3)ReliabilityHigh AvailabilityFault TolerantModular I/O

Configuration softwareCertified Configuration EnvironmentEasy to Use

Interface to existing BPCS or HMIOpen Protocol (i.e. Modbus)Easy to UseBidirectional (READ/WRITE)

Bypass and maintenance override facilities



Contents



Certificates


Engineering

Operation

Maintenance

Security

Integrated engineering environment

Streamlined deployment and operational performance

Graphical function design

Reusable solutions

Operator graphics

Change management

Integrated documentation

EngineeringCommon environment



Engineering Compiler Restrictions

The compiler warns and / or prevents the engineer from designing dangerous code

For example complex code structures, loops etc

The compiler checks that all restrictions and rules necessary to achieve the intended SIL of the application are adhered to

An error is reported when a rule is violated and the attempted download to the controller is blocked


Engineering On-line changes

Online changes can be downloaded to the controller without interfering with the running process

FB/CM parameters (e.g. trip limit)

Hardware settings (e.g. ISP value)

Logic

Downloads are protected by the “Access enable” function

Re-authentication can be configured to ensure that the user is authorized

This is also recorded in the audit trail


Engineering Certified Libraries

System

AlarmEventLib

BasicLib

FireGasLib

MMSCommLib

ProcessObjBasicLib

ProcessObjExtLib

SerialCommLib

SignalBasicLib

SignalLib

SignalSupportLib

SupervisionBasicLib

SupervisionLib


Contents



Certificates


Engineering

Operation

Maintenance

Security

800xA enables streamlined routine work processes and optimal reaction to upset conditions

Process Portal provides:

The ability to display information from multiple sources and transform it into relevant information for a diverse set of plant users.

Personalized workplaces for focused information access

Maintenance supervisors, process engineers, managers and plant operators etc.

User profile based upon security log-in

OperationPersonalized workplaces for safety



OperationExample Operator Display

Personalized Workplace for Safety Personnel


Operation Operator Interaction – Confirm On-Line Write

Time out handling in Safe On-line Write dialog (90 seconds)

Provides operators with a visual feedback and requires them to confirm the operation before execution


Contents



Certificates


Engineering

Operation

Maintenance

Security


MaintenancePartial Valve Stroke

SIL3 safety valve controller

Emergency shutdown (ESD)

Emergency venting (ESV)

Enable integrated PST functionality

Launching a PST

Manual (DTM)

Local user interface (LUI)

Local control panel (LCP)

Scheduler (DTM)

DTM

Search engine for System 800xA (Aspect Object database)

Reports can easily be exported to Excel(two mouse clicks)

Examples of searches include:

Forced IO signals

Inhibited Function Blocks

Valves in Manual

Transmitters over a limit

Loaded as a system extension

Snapshot Reports aspects

Snapshot Report Template

Snapshot Report Viewer


MaintenanceSnapshot Reports


Contents



Certificates


Engineering

Operation

Maintenance

Security

Users can be assigned with different permissions according to their responsabilities

Restriction of access to the SIS (operation and engineering)

High flexibility

SecurityRoles & Responsabilities

Pro

cess

O

pera

tor S

afet

y O

pera

tor P

roce

ss

Eng

inee

r Saf

ety

Eng

inee

r

Operate BPCS X X

Operate SIS X

Engineer BPCS X X

Engineer SIS X



SecurityMulti-authentication

OPC properties can be configured to require an explicit authentication operation before the operation can be performed

Re-authentication

Double authentication

Intended for process critical operations

The information is stored in the Audit Trail (including reason and comment)

If the authentications fails three times in a row the dialog box is terminated and a system alarm is reported to the administrator


SecurityAudit Trail

The Security and Access Control System enable audit of all operator and engineering actions

Filtering of the audit event categories

Possible to disabled during commissioning (system administrator)

Audit actions examples

Alarm acknowledged

Configuration changed

Signal forced

Download

Reserved/Released

Daniele Corali, ABB SpA – Process Automation Division ... · 800xA High Integrity – ABB Safety...

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