[ppt]powerpoint-presentation - abb group · web viewmaking the plant site a safe environment...

© ABB Group May 6, 2023 | Slide 1

Innovation and leadership in SafetyABB Overview

Agenda

ABB understand the Process Industries and its Risk Safety is about Risk Reduction International Safety Standards continues to evolve Innovation and leadership in Safety over 30 years The Power Of Integration and its relevance to Safety The advantage of Integrated Safety Safety Execution Centers the human factor References


© ABB GroupMay 6, 2023 | Slide 3

Process Safety Market is growingRespond to energy demand at reduced production risk


Balancing operations in the Process Industries

Companies have a legal, moral and financial obligation to limit risk posed by their operation.

Human factors, environment, operational risk, cost

Build the lowest cost plant, keep operating budget as small as possibleComply with regulations

as written, regardless of cost or actual level of risk

Make plant as safe as possible, disregard cost

Moral

FinancialLegal


Safety is about Risk Reduction

Residualrisk

Processrisk

RiskTarget

Increasingrisk

Necessary risk reductionActual risk reduction

Risk reductionleft to be

handled by theSafety

InstrumentedSystems

SIS

Risk reductiondue to other technology:-fire pumps, -foam systems, -water curtains, -deluge systems(hydraulic, pneumatic )

Calculated Process RiskTolerable Level of Risk(Defined by user per application)

Risk reductiondue to mechanicalequipment like: - relief valve, - non return valve,- dike…


Evolution of Safety StandardsFrom prescriptive to performance based

USA

Inte

rnat

iona

lG

erm

any

UK

1995

IEC SC 65 IEC 61508

ISO 10418

DIN VDE 0801

DINVDE 19250

HSE PES

OHSA CFR1910.119

ISA dS84.01

API RP14C

1995Draft

1995Draft

1993

1991

1989

1987

1974

ANSI/ISAS84.01

1999

2005

IEC 61511 2003

1996

1992

1974

, Flix

boro

ugh

1976

, Sev

eso

1984

, Bho

pal

1986

, Che

rnob

le

1988

, Pip

er A

lpha

1989

, Pas

aden

a

PRESCRIPTIVE STANDARDS

PERFORMANCE STANDARDS

ANSI/ISAS84.00.01 (IEC 61511 Mod)

2004

New installations must conform to IEC 61511

Protection is implemented in multiple layers

SIL 0-1

SIL 2

SIL 3



30 Years Of Experience With Safety SystemsPioneering Installations & Long-Term Support

First safety system delivered offshore to the North Sea in 1979

Pioneering engineering efforts Close collaboration between ABB

and end-users Long customer relationships with close

technical support and system evolution Installed base continuously evolved

and migrated to maximize customer value and minimize risk

Support throughout system life-cycle from installation to de-commissioning

“ For an ocean of safety experience you can

trust...”


Over The Years…Innovation and leadership And our experience continues to grow

1975 1980 19901985 20001995 2005 2010+1979 - Statfjord B safety system goes online

1983 – Safeguard 9000

1984 – First integrated MP200 based safety systems goes online at Gulfaks A platform

1993 – Safeguard 3000 1997 – Safeguard 400

1993 – First integrated Safeguard 3000 safety system goes online at Sleipner A platform

2002 – Plantguard

2005 – 800xA High Integrity

(SIL2)

2008 – 800xA High Integrity

(SIL3)

2007 – Largest HI system to date (13 000 IOs) goes online

2005 – First installations with Safeguard and HI in parallelK

ey P

roje

cts

Pro

duct

s

1979– Triguard

Over The Years…First Integrated System And Worlds Largest Platform

Control system evolution of integrated process control and safety systems solution optimize safety and controlWhen the Gullfaks A platform went online in 1984 it featured the very first large scale integrated Process Control and Safety System, essentially constituting the starting point for ABB’s 25+ years experience with integrated safety systems. Live (no shutdown) retrofit of Control and Fire&Gas systems through 3 generations of systems.The largest platform on the planetTroll A is the largest platform ever built. It produces about 75 million scm of natural gas and 10,000 bpd of NGL condensates per day. The original Infi90 based control and safety system for the platform was delivered in 1995. When the new integrated safety system went online on June 5, 2009 it was the first SIL3 certified 800xA High Integrity installation in the world.

Gullfaks A, North Sea

Troll A, North Sea

Access to information…Seamlessly and in context


System 800xA HI – Integrated SafetyCustomer value of integration – available today

Plant-wide Sequence of Events

Same operations interface and engineering

Centralized Historian and

Data Archiving

Centralized Historian and

Data Archiving

Common, integrated asset management

strategy

Common system therefore reduced

spare parts, training etc…Process control

and safety in the same HI controller Centralized

Historian and Data Archiving

Process control and safety running in

separate controllers


The Advantage of Integrated Safety

Potential common cause are analyzed and minimized during the design phase by the product development team and independently reviewed by the assessor during the certification of the product

Access control is implemented as a standard off-the shelf feature including write protection and bypassing and override mechanism

Integrated testing is performed during the design validation and verification test, which includes also Network Security as part of the test protocol

Version control, compatibility and interoperability testing are all part of the release procedure



What is the scope of TÜV Certification?800xA High Integrity – ABB Safety Certificates

Product Safety Certificate

Development Department Safety Certificate

Safety Manual


PPA

Engineering Client

Operation Client

High Integrity I/O

High Integrity Controller

SM811

PM865

BC810

DO880

DI880

AI880

TB840

Control Network

CI854

SM811 Synchronization link (RJ45)

CEX-bus interconnection

Modulebus

RCU link

Profibus

Is the “Integration” part of the Certification Process?Absolutely , It’s Interference Free

Optical Modulebus

Safety certified Safety relevant Interference-free


800xA High IntegrityDiverse Architecture, Diverse Implementation

The SIL 3 800xA High Integrity controller has parallel processing paths based on diverse technology

Integrity voting between paths compliments the built in active diagnostics

Controller and Supervision Module developed by diverse (different) teams (Vasteras and Malmo, Sweden) and tested by a third team (Oslo, Norway) by people with different backgrounds

The two channel architecture meets SIL3 requirements for hardware fault detection and reaction

1oo1D 1oo2D

90 - 9960 - 90< 60

0SFF (%)

SIL 3SIL 2SIL 1

1SIL 1SIL 2SIL 3SIL 4

HFT

> 99

IEC61508-2 Table 3

PM

SM Safety I/O SIL3

CBSIL3

AC800M HI SIL3


Diversity: Software and Hardware

Software diversity Different operating systems Different base software layers Different un-packing procedures

Hardware diversity Diverse execution paths based on different hardware

technology such as MCU and FPGA

a11

a22

3a3

4a4

b1

b2

b3

b4

5

6

7

8

Vcc1

GND

0 0

GND

0 0

Vcc2

MPU

a11

a22

3a3

4a4

b1

b2

b3

b4

5

6

7

8

Vcc1

0

GND

0

RAM

a11

a22

3a3

4a4

b1

b2

b3

b4

5

6

7

8

Vcc1

0

GND

0

FPGA

&0

0

0

READ CODE


SecuritySystem Security And Embedded Firewalls

Provides functions for protection of SIL classified applications in AC800M HI Controllers

SIL Access Control and Authorization Force Control / Override Control /

Bypass Management Confirmed Online Write / Confirmed

Operation Embedded firewalls and confirmation

procedures protect the SIL application from inadvertent / accidental control actions

SecurityRoles & Responsibilities

Users can be assigned with different permissions according to their responsibilities

Restriction of access to the SIS (operation and engineering)

High flexibility


Process Operator

Safety Operator

Process Engineer

Safety Engineer

Operate BPCS X X

Operate SIS X

Engineer BPCS X X

Engineer SIS X


Thanks to a Common Operation Environment……Operator can take timely action

Monitor the Process and respond to Abnormal Conditions

More Efficient and Effective TroubleshootingSafety relevant information is readily available

Alarms, Events, Audit Trail, and SOE displays for root cause analysis

Real-time information Standard functionality for

inhibiting of specific safety functions

Status supervision of Safety System Elements

Flexible Report Creation and Scheduling

Valve Leak Test, Verification, Automatic Shutdown Reporting, SIL status



25 Years With Fully Integrated Safety SystemsFully Leverage System 800xA Capabilities

Integrated safety system implementations enable end-users to fully leverage System 800xA functionality across the entire automation system

Information Management / Reporting Alarm Management/Sequence Of Events Asset Management Engineering Etc…

Fully flexible system configuration capabilities enable tailored systems solutions Systems designed according to application and end-user requirements Integration is fully optional and allows customized degrees of separation

based on customer requirements Cost optimization and end-user satisfaction go hand in hand


25 Years With Fully Integrated Safety SystemsExperience And Know-How

ABB has been installing and operating integrated safety system for 25 years without incidents

The first fully integrated Safeguard system was installed at the Gullfaks A platform in 1984

The latest generation ABB safety system 800xA High Integrity offers market leading integration capabilities

Enabling significant cost reductions throughout systems lifecycle

“ While others have been debating it ABB

has been doing it. Operating for 25 years to the benefit of end-

users and without incidents...”


Installed BaseInstallations Across The Globe

ABB’s intimate knowledge of and experience from all conceivable locations, environments and applications directly benefits end-users

With more 30 years on the market the installed base is spread across

…more than 55 countries… …on all continents and across all

regions… …and all traditional safety systems

industry segments such as oil & gas, petrochemical and chemical industries…

…as well as more non-traditional safety systems industry segments such as pulp & paper, semiconductor and minerals & mining facilities.

“Reducing risk where it is needed…”

More than 3,000 controllers sold since initial release in January 2005

© ABB Control SystemsMay 6, 2023 | Slide 27

30 Years Of Experience With Safety Systems ABB Safety Execution Centers

Safety Execution Center (SEC)

TUV Certified SEC

Conclusion

ABB has been a leader and an innovator in the area of Safety Automation

800xA provides information to rapidly convey critical operating conditions consistently enabling Operator Effectiveness , specially under abnormal conditions

800xA High Integrity is the latest example with its innovative use of diversity of design to provide a safe and reliable safety system

ABB has over 30 years of experience in Safety, reflected on the global installed base and accumulated application experience in the Safety Execution Centers


[ppt]powerpoint-presentation - abb group · web viewmaking the plant site a safe environment...

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