High Availability and Safety solutions for Critical Processes

High Availability and Safety solutions for Critical Processes An Introduction to AADvance Subrahmanya Bhat P Sr. Systems Engineer 09 & 10 th Sep 2014 PUBLIC INFORMATION Rev 5058-CO900E

2 Agenda Process Safety Introduction AADVANCE Product Introduction AADVANCE Scalable Redundancy, Flexible Architectures AADVANCE Workbench Integrated Control & Safety

3 Agenda Process Safety Introduction AADVANCE Product Introduction AADVANCE Scalable Redundancy, Flexible Architectures AADVANCE Workbench Integrated Control & Safety

4 Enhancing the Value of Safety Protect People, Environment & Assets Enhance system safety with flexible, scalable safety solutions Lower costs by deploying an integrated safety architecture Obtain maximum availability and reliability with proven safety technologies Reduce risk by leveraging the knowledge of safety experts Lower troubleshooting time and costs with Intelligent Motor Control Reduce the risks associated with the operation and maintenance of electrical equipment with safety Motor Control Centers Reduce downtime and maintenance costs by protecting rotating assets

5 Key Characteristics and Features of a Safety Integrity System (SIS) Functional Requirements SIL Capability Fail Safe Or/And Fault Tolerant Performance Key features (Benefits) Size Connectivity Flexibility

6 Agenda Process Safety Introduction AADVANCE Product Introduction AADVANCE Scalable Redundancy, Flexible Architectures AADVANCE Workbench Integrated Control & Safety

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8 AADvance Core Components Controllers Workbench Portal Network Logic Solvers Processor modules I/O modules Termination Assemblies Mechanical Engineering Workstation For Configuration, Programming and Maintenance OPC For Connectivity to Operators, Historian, Alarm management, etc. Safety Network For distributed safety applications and information exchange between controllers

9 AADvance Hardware Components Redundant Communication Ports Redundant Terminations(TA) CPUs CPU Base Input Module I/O Base Unit Output Module

10 Agenda Process Safety Introduction AADVANCE Product Introduction AADVANCE Scalable Redundancy, Flexible Architectures AADVANCE Workbench Integrated Control & Safety

Controller Scalability in Size and Redundancy PUBLIC INFORMATION 11 Flexible Architectures TA Each input slot group can be configured for simplex (1oo1D), dual (1oo2D) or triplicated (2oo3) TA Controller base allows simplex, dual or triplicated processor configurations and connections to 48 I/O module slots Each output slot group can be configured for fail-safe (1oo2D) or fault-tolerant (Quad) I/O backplane CPU Base/backplane I/O Backplane

12 Portal & Network Scalability & Connectivity Workstation Workstation portal NAS Ethernet based Safety Network

13 Scalable Redundancy Simplex (SIL 2) 1oo1D Fail Safe Certified for use in SIL2 applications TA TA I/P CPU O/P

14 AADvance Controller Simplex CPU Base with one CPU populated I/O Base with one input and one output fail safe

15 Scalable Redundancy Simplex (SIL3) 1oo1D/1oo2D Fail Safe Certified for use in SIL3 applications TA TA I/P CPU O/P

16 AADvance Controller Simplex IO, FT CPU Redundant CPUs

17 Scalable Redundancy Redundant (SIL3) 1oo2D/2oo3 Fault Fault Tolerant Tolerant Certified Certified for for use use in SIL3 in SIL3 applications TA TA I/P CPU O/P

18 AADvance Controller Redundant Redundant CPUs Redundant Terminations Redundant inputs Redundant outputs

19 Scalable Redundancy TMR (SIL3) SIL3 TMR Fault Tolerant applications TA TA I/P CPU O/P

20 AADvance Controller Triplicated Triplicated CPUs Triplicated Terminations Triplicated inputs Fault Tolerant outputs

21 Input Architecture Dual TMR Simplex 1oo2D 2oo3 1oo1D TA I/P Module Processor IO Driver Logic 4-20mA 4-20mA PP P PV (2oo3) (1oo2D) (1oo1D) H HART

HART Passthru PlantPAx Local Architecture Ethernet AMS HART Passthru Data is passed to/from an AMS Workstation through the AADvance controller to the Field Device. 4-20mA 4-20mA PUBLIC INFORMATION Smart Transmitter AADvance System Smart Positioner 22

23 Output Architecture Dual Simplex TMR Processor 1oo2D 2oo3 1001D & Quad Output Processor O/P Module TA Logic Logic Logic CMD CMD CMD IO Driver IO Driver IO Driver A 2oo3 1oo1D 1oo2D A D D 24v A 24v B B 2oo3 1oo1D 1oo2D B D D 1oo2D QUAD

24 Distributed Architecture Safety Network Control Protocol (SNCP) Remote I/O Trusted TMR LSLL101 SDV102

Safety and Critical Control High Availability Process Control High availability solutions from redundant I/O to redundant controllers, resilient networks to redundant HMI servers Scalable Process Safety Integrated BPCS and scalable SIS solutions, including TMR for the highest availability SIL 0 Process Control SIL 1 Fail Safe SIL 2 Fail Safe SIL 2 Fault Tolerant SIL 3 Fail Safe SIL 3 Fault Tolerant Economical risk reduction by protecting only critical assets PUBLIC INFORMATION

26 Flexible Architecture Summary Processor configurations SIL levels I/O channels I/O connections I/O configurations Output options Safety network Communications Standards AAdvance Processors configurable for simplex, dual, triplicated modes, including integration of Trusted TMR technology Rated and suitable for SIL1-3 applications 8 and 16 channel SIL3 fail-safe modules 48 I/O slots connected to each controller. Configurable as simplex, dual or triplicated Configurable for fail-safe or quad outputs Safety networks allow multiple controllers and I/O to be connected for distributed applications Integrated Connectivity with CLX devices through Networked connection (CIP) Architecture wide Connectivity with 3 rd party devices through AADvance portals (OPC) Controller Connectivity with 3 rd party devices through direct or networked connection (MODBUS ) TUV IEC61508, NFPA 72,85, IEC1131

27 Agenda Process Safety Introduction AADVANCE Product Introduction AADVANCE Scalable Redundancy, Flexible Architectures AADVANCE Workbench Integrated Control & Safety

Workbench Languages PUBLIC INFORMATION 28 All 5 IEC 61131-3 languages.

29 Workbench Multi-Controller Environment SIL 3 Safety Data links between Train 1 & 2

30 Workbench Collaborative Environment Checked In Checked Unavailable Out for Modification Available for Modification

31 Workbench Simple Hardware Configuration Select Module Type and Architecture.

32 Workbench Simple Point Configuration You now have a Scaled Analog Input Providing: Input in Engineering Units Three Standard Fault alarms. Status Word for Transmitter Faults Connect Enter the Instrument a Field Range. Device Tag.

33 Workbench Enhanced Point Configuration You can also configure device specific fault thresholds for Overange, saturation, open circuit etc. Defaults follow NAMUR NE47 You now have HART Data Providing: Transmitter 4-20mA Current Transmitter Process Value Three Device HART Values HART Status HART Communication Status Assign a single HART Device Tag.

34 Workbench Version Control & History View History. Get Differences.

35 Workbench Program Simulation Simulate & test programs offline!

36 AADvance System Summary Product Standards Environmental Specification Mechanical Specification Electrical Specification Application Standards Maintainability Safety Integrity : TUV IEC61508 (SIL 3), Programming: IEC1131 (All Languages) Electrical Safety: UL508, CSA 22.2 Hazardous Area: UL, CSA, ATEX (Class 1 Div 2/Zone 2) EMC: IEC61000-6 Module Housing: IP21-25 o C (-13 o F) to +70 o C (+158 o F) 10% to 95% RH, non-condensing Shock: 15g, 11mS duration Vibration: 10Hz to 150Hz, 0.1g, all 3 axis Module Supply: 18VDC to 32VDC Field Supply: 18VDC to 32VDC Isolation: 1500VDC Process Industries: IEC61511 Power Industries: EN50178 Burner Management: EN50156, NFPA 85, NFPA 86 Fire Protection: EN54, NFPA72 All Modules support Hot Replacement. All Modules are physically Keyed to prevent incorrect module insertion.

37 AADvance Processor Summary Processor configurations Module Power Module: 8.0W Processor Memory Communication Ports Communications Protocols Safety network AADvance Processors can be configured in Simplex (1oo1D), Dual (1oo2D) & Triplicated (2003) modes Program Storage: 64Mb Flash Memory Runtime Storage: 32Mb SDRAM 2 x 10/100 Base T Ethernet and 2 x 115Kb RS485 Serial ports on each processor module Integrated Connectivity with PlantPAx Controllers using Ethernet I/P (CIP) Architecture Connectivity with Automation Systems using the AADvance OPC Server Architecture Connectivity with Field Devices using the AADvance HART DTM Controller Connectivity with 3 rd party devices through Ethernet or Serial connections (MODBUS ) SIL 3 Safety network (Black Channel) allows multiple controllers and I/O to be connected for distributed applications Safety Data Safe Failure Fraction (SFF) > 90% SIL 2 (Simplex) SIL 3 (Dual or Triple) Typical PFDavg figures for 8hr MTTR & 1 yr Proof Test Interval (TI) Simplex 1.20E-04, Dual 4.58E-07 & Triplicated 5.15E-07

38 AADvance I/O Summary Input configurations Module Power 8 Channel Inputs: 3.3W 16 Channel Inputs: 4.0W Input Range Safety Data Output configurations Module Power Digital Outputs: 3.0W Analog Outputs: 3.6W Output Range Safety Data AADvance Input Modules can be configured in Simplex (1oo1D), Dual (1oo2D) & Triplicated (2003) modes Digital Input: 0 to 30VDC (0-5VDC = OFF, 15-30VDC=ON) Analog Input: 0 to 24mA (NAMUR NE47 Transmitter fault alarms and HART CMD#03) Safe Failure Fraction (SFF) > 99%, SIL 3 (Simplex, Dual or Triple) Typical PFDavg figures for 8hr MTTR & 1 yr Proof Test Interval (TI) Simplex 3.89E-06, Dual 4.28E-07 & Triplicated 4.28E-07 AADvance Output Modules can be configured in Simplex (1oo2D) & Dual (Quad) modes Digital Output: 0 to 32VDC, 1.0A per channel, 10A Inrush for 50mS Analog Output: 0 to 24mA (HART CMD#03) Safe Failure Fraction (SFF) > 99%, SIL 3 (Simplex, Dual or Triple) Typical PFDavg figures for 8hr MTTR & 1 yr Proof Test Interval (TI) Simplex 1.37E-05 & Dual 2.73E-06

39 AADvance Workbench Summary Supported Operating Systems Supported Languages On-line monitoring Windows Server 2003 & 2008, Windows XP SP3, Windows 7 and Windows Vista. Both 32 and 64 bit versions IEC1131-3 compliant languages Ladder, Function Block, SFC, ST, IL. All code generated by the WB is TUV certified Monitor running applications (programs and variables), force I/O On-line programming Off-line simulation Version control Security Distributed applications Modify applications in controllers, add/delete programs, variables and I/O modules Simulate 100% applications before downloading Integrated version control and multiple user/project access Password and Hardware Security Support distributed applications across multiple AADvance processors and multiple workstation access

41 Agenda Process Safety Introduction AADVANCE Product Introduction AADVANCE Scalable Redundancy, Flexible Architectures AADVANCE Workbench Integrated Control & Safety

42 Integrated Control & Safety PlantPAx Operator Interface FT View HMI Data Server CIP Network (EtherNet/IP) Control System (BPCS) Safety System (SIS)

43 Integrated Control & Safety AADvance Connectivity FT View Clients displaying data from Logix and AADvance/Trusted FT View HMI Data Server CIP Network (EtherNet/IP) FTD Configuration Monitoring ICST OPC Server As a FTView Data server Safety Network AADvance Controller AADvance Enabled Trusted Controller AADvance and Trusted communicate with Logix via EtherNet/IP using both Class 3 CIP Connection OPC connectivity RSLogix5000

Rockwell Automation Safety Solutions Cost effective approach to risk management The right degree of protection and fault tolerance Helps manage Capital and Operating Budgets for from an automation asset perspective Migration strategies & expertise Environmental Compliance Critical Control Solutions which assure asset integrity Reporting packages to support compliance Solutions to help maintain process boundaries; protecting people, assets & the environment Fit for Function/Purpose hardware design Take the risk out of applying safety systems Efficient space requirements Over 40 years of deploying Safety Solutions Knowledgeable People including Functional Safety Consultants Safety expertise to help determine what is needed to operate safety Expertise to provide the linkage between behavioral safety and process safety PUBLIC INFORMATION 44

Services for a Risk Based Approach Functional Safety Consultancy Certified Functional Safety Engineers Risk Based Assessment Management IEC 61508 process SIL Assessment Training Validation and Compliance PUBLIC Copyright INFORMATION 2011 Rockwell Automation, Inc. All rights reserved. 45

Questions? PUBLIC INFORMATION Rev 5058-CO900E

For additional information PlantPAx: www.plantpax.eu O&G information: http://oilandgas.rockwellautomation.com/en/ Download Process Safebook: http://www.emea.rockwellautomation.com/ Check out the Process, Safety demo on the show floor Request a PlantPax Demo: http://www.emea.rockwellautomation.com/process Join us at PSUG & AF: http://www.rockwellautomation.com/rockwellautomation/events/automationfair/overview.page