How To Communicate Safely

Transcription

1 Fieldbus Foundation Safety Fieldbus for Process Automation FF SIS (SIF) Trygve Harvei 1

2 ABB Corporate Research Center Research and Development within the area of automation networks at Billingstad (Oslo, Norway) One important topic is Safe Communication About 22 scientists in Oslo Integrated part of Scandinavian Corporate Research Center and Global Lab for Automation (ca 700 scientists) Work together with different ABB business units on research activities and front-end technology development Process Automation Automation Products Power Systems Power Products Robotics 2

3 IEC "Functional safety of electrical/electronic/program mable electronic safetyrelated systems". IEC has the following views on risks: zero risk can never be reached safety must be considered from the beginning non-tolerable risks must be reduced (ALARP) TÜV Rheinland, approval 3

4 What do we need to ensure with safe communication? Communication: We must know that the values of the data we receive is right We must know that the data is not too old We must know that the data is received from the right node to the right node This is the purpose of the layered protocols such as TCP/IP or others? Yes, but the probability calculations for errors is not good enough 4

5 Some Industrial Safety Protocols CIP-Safety DeviceNet Ethernet/IP PROFIsafe PROFIBUS DP/PA PROFINET FF H1 Vendor specific ABB (Ethernet) Hima (Ethernet) PILZ Others 5

6 Motion Control and Safety Source: ARC 6

7 Safety Measures in safety protocols Transmission error Number sequen ce Time stamp Identifier for sender & receiver with watchdog timeout Data integrity assurance (CRC) Receipt acknowledgement Redundancy with cross check Different data integrity assurance systems for safety & standard messages Message repetition Loss of message Message insertion Sequence failure Data SB corruption only Delay Masquerade 7

8 Safety Instrumented System (SIS) FF SIS New approach to SIS Defines control in the field Function blocks for building safety applications Shared with host Distributed PROFISAFE PA PROFISAFE transparent to media Utilizes black channel approach 9 ESD: emergency shutdown system SIS: safety interlock (or instrumented) system BMS: burner management system F&G: fire and gas system

9 PROFIsafe wire representation Ethernet ramme på kabelen: Sikkerhets bitene i Ethernet rammen: 10

10 Foundation Fieldbus extension - FF SIS scope Safety Instrumented Systems n Extends FF Technology to Safety Instrumented Systems n Based on the IEC International Standard. n Example Application Areas: Burner Management Systems Fire & Gas (petrochemical) Fuel Engineering 11

11 International Development Team ABB AS ABB Instrumentation BIFFI E.I. DuPont de Nemours, Inc. ExxonMobil Research & Engineering Emerson Process Management Flowserve HIMA Honeywell SMS ice-pros Infraserv Höchst Technik GmbH & Co. KG Invensys/Triconex Metso Automation Rockwell Automation Rotork Control Systems Saudi Aramco Smar Shell Global Solutions Softing AG TÜV Westlock Controls Corporation Yokogawa Electric Corporation Yokogawa - SCE Yokogawa UK Limited Norway Italy Italy USA USE USA USA Germany The Netherlands Canada Germany USA Finland USA UK Saudi Arabia Brazil and Singapore The Netherlands Germany Germany USA Japan The Netherlands UK 12

12 Scope n Extends FF Technology to Safety Instrumented Systems n Based on the IEC International Standard. n Example Application Areas: Burner Management Systems Fire & Gas Fuel Engineering 13

13 End User Requirements n n n 14 Reduced Total Cost of Ownership for applications. CAPEX Hardware, Footprint, Commissioning, Power Consumption OPEX Advanced diagnostics, Reduced test interval via increased DCF. SIL 2 and 3 applications Password protected access to field devices n Additional Function Blocks (e.g. logic, 2 out of 3 voting) n n Definable actions on diagnosed failures trip, message Handle discrete signals (e.g. switches, motor trips, lights, push buttons, etc.) where H1 dynamic performance is acceptable

14 End User Requirements 15 n Total system approach Total Asset Management and Non-SIS Modular Logic Solver centralized and distributed option Diagnostics Hybrid system architecture & traditional hardware Guidance to manual proof test Signalling/procedures for auto proof test Awareness of opportunity-based proof test Logging/documentation of results Failure rate updates

15 Extension Areas n Communication Meet IEC part 2 clause Communication Diagnostics n User Application Meet IEC part 3 clause Function Block Diagnostics CRC on Device Description Files 16

16 Process Safety Time/ Safety Function Response Time Stale counter must be applied in accordance with the specific application 3x communcation timeout as thumb rule 17

17 FF Scheduling of communciation and FB execution 18

18 FF H1- Slow but accurate & safe? The PID control algorithm depend on the sampling of process values + filtering 19 Time Polled approach PLC cyclic IO Copy Jitter + drift introduces I&Derrors Synchronized approach FF -In loop execution of sampling and control algorithm The analog SIS voter can rely on fresh values -> best possible Process Safety 1 ms synch accuracy Alarm

19 Communication Extensions n Black Channel Approach H1 Communication System (Black Channel) is unchanged. A new protocol above the Black Channel detects network faults and appropriate action is taken without human intervention. IEC New Communication Diagnostics Black Channel IEC

20 User Application Extensions n User Application New Function Blocks for Applications FBAP Part 6 New FBAP diagnostics detect application faults and appropriate action is taken without human intervention. IEC New Function Blocks & Function Block Diagnostics Black Channel IEC

21 User Application Extensions Function Block Application Process Part 6 SIS Write Lock SIS Discrete Input SIS Analog Input SIS Discrete Output SIS Analog Voter SIS Discrete Voter SIS AND/OR/XOR Diagnostics and Statistics added to device Resource Block 22

22 Today s Proprietary SIS Operation Engineering Proprietary Network SIS Logic Hardwired 23

23 Tomorrow s Open Operation Engineering Operation Engineering Total Asset Management Proprietary Network SIS Logic HSE H1 Linking Device Ethernet Switch. Logic. Solver?.. Linking Device H1 Hardwired Devices Non-SIS FF Devices 24 Logic Solver

24 System topology for process safety Plant Network / Intranett Arbeidsstasjoner Enterprise Optimization Suite Firewall Tredje part applikasjon server Mobile Operator Client/server Network Connectivity server Aspect server Application server Engineering Arbeidsstasjoner Control Network Control/ PLC ESD SIL 3 PSD SIL2 F&G SIL 2 Seriell kommunikasjon/felt buss 25 Trenger sikker (safe) kommunikasjon på Kontrollnetverks-nivå og på felt-nivå. Delevis på operatør-nivå

25 Increased diagnostic coverage with The instruments and actuators are included in the safety system and becomes part of the diagnostic testing The increased diagnostic coverage Makes it possible to at an early stage do repair in many cases No longer proven in use certification TÜV will not accept the proven in use concept for devices 26

26 Effects of increased diagnostic coverage 27

27 Example Application WL RB AI WL RB AI AVTR DO DI WL RB AI WL RB Write Lock S 28

28 Example Application WL RB DI WL RB DI DVTR LOGIC DO DI WL RB DI WL RB Write Lock PS PS PS WL RB DI S Estop 29

29 New Kid on the Block USER LAYER DD IEC OSI Model USER LAYER USER LAYER DD IEC USER LAYER DD IEC IEC APPLICATION LAYER 7 IEC FMS IEC FDA 6 5 PRESENTATION LAYER SESSION LAYER COMMUNICATION STACK 6 5 COMMUNICATION STACK 4 TRANSPORT LAYER 4 IETF TCP/UDP 3 NETWORK LAYER 3 IETF IP 2 1 DATA LINK LAYER PHYSICAL LAYER 2 PHYSICAL LAYER 1 IEC DLL IEC kbit/s IEEE MAC IEEE 100 Mbit/s PHYSICAL LAYER H1 HSE H1/HSE 30

30 Target Schedule Q FF Board of Director Approval for SIS Project Q Project Kickoff Meeting 2Q Architecture Completed 3Q Draft Preliminary Specifications (DPS) Version 0.4 4Q TÜV Concept Approval for SIS Q DPS Version 0.5 External Review 2Q Release DPS Version 1.0 3Q Develop Lab Test Tools and Lab Prototypes 4Q Begin Specification Validation Lab Infraserve in Frankfurt 2005 Release SIS Specification 1.0 and Final TÜV Type Approval 2008 FF SIS Rollout Team 31

31 FF SIS demonstrators - SROT 32