Veronafiere ottobre Gli atti dei convegni e più di contenuti su

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1 Veronafiere ottobre 2017 Gli atti dei convegni e più di contenuti su

2 DCS - SIS integration: methodologies and functions. A. Padovani, Yara M. Veronesi, Yokogawa 1

3 1. Segregation vs. Integration 2. Safety certified communication 3. Benefits of a single platform ICSS 4. Conclusions 2

4 Segregation vs. Integration 3

5 Safety Risk reduction! Safety standards IEC61508 IEC61511 Page.4

6 Protection Layers

7 How to meet different point of view? Safety (IEC61511) Segregation Separation Safe operation Plant optimization Integration Ergonomics Availability Page.7

8 The Integration between ESD and DCS (1) HMI EWS ESD as a subsystem DCS ESD ESD Eng. - Multi-vendor solution - Physically separated networks - different networks additional modules required (Modbus, Profibus,..) - typically slower (serial) communication - poor embedded HW diagnostic - heavy engineering (comm. Register map, alarms..) - No integrated SOE Page.8

9 The Integration between ESD and DCS (2) ESD in the OPC network DCS HMI EWS OPC server ESD ESD Eng. - Multi-Vendor Solution - Physically separated networks - ESD data available for all OWS / HMI in the network - Redundant OPC (DA + A&E) server needed - Data not always available for DCS controllers - Limited HW diagnostic - Additional engineering for OPC (automatic browser not always available) - Different functionalities for DCS tags and OPC tags Page.9

10 The Integration between ESD and DCS (3) EWS, HMI ESD Eng. ESD in the System Network DCS ESD More integrated solution (*): may reduce layers of protection - Single-vendor solution - one (redundant) certified network - High-speed communication - Full built-in HW diagnostic + system reserved switch - no additional engineering at DCS side - Integrated alarm list and SOE - One single HMI style (safer operation!) - Integrated Instrumentation Management System (AMS) - Partial stroke testing - One single data gateway to the PIMS/MES level Page.10

11 ProSafe-RS & CENTUM VP/CS 3000 DCS

12 Safety Communication 12

13 True Integration of DCS and SIS Data exchange between Safety controllers -> TUV approved Safety Communication. Data access to Safety Controller -> No interface module is required. HIS Vnet / IP Safety communication Safety Data to FCS Safety Controllers No affects to safety communication Page.13 DCS Controller

14 Band segregation and Domain segregation Bus 2 PIMS Open OPC Open Vnet HIS Open Vnet HIS Open Vnet Open communication Control communication HIS-HIS communication PLC communication Control communication Bus 1 Vnet FCS Open Vnet APCS Open Vnet GSGW Open PLC Page.14

15 Time synchronisation Synchronization through ICSS Network Page.15

16 Additional Safety Layer CENTUM VP HIS Vnet/IP Safety communication Non safety communication No affects to safety communication Safety Data Safety Layer Safety Data Safety Layer Non safety Data Non safety Data Application Layer Data link Layer Physical Layer Black Channel

17 SIL3 inter-scs Communication Additional safety layer In place of the application layer Encryption, CRC, watch-dog Sequence nr., timestamps Reserved memory for safety data Task priority: safety functions executed even in case of endless loop of non-safety routine Password control for download operation and override execution No failures on ICSS network communication can affect the safety function! Page.17

18 Safety Communication inter SCS SCS Sender (Producer) VNet Status Value SCS Receiver (Consumer) Value Status Value Diagnostic Block Diagnostic SYS_DIAG Function Block Producer Function Block Consomer Block Diagnostic SYS_DIAG Encrypted Variables ICSS Network Safety communication Encrypted Variables Page.18

19 Benefit of an single platform ICSS 24

20 Benefits from the integration Same HMI Single navigation Same faceplate (higher safety when operators are in troubles) Same Trends views Same Alarms/Event management Similar HW diagnostic High-speed redundant communication Domains segregation Integrated Engineering of 2 segregated platforms No communication maps (read/write, byte/word/float etc..) Integrated FB shared with DCS by equalization System reserved diagnostic bits available Integrated Instrument Management Systems (Partial Stroke) One single port to upper layers systems (PIMS, MES, APC) Page.25

21 Same OWS for DCS and SIS Tag access from/to HIS to SCS HIS - Faceplates - Trends - Graphics - System views - Alarms - SOE ICSS Network ProSafe-RS SCS Centum FCS Page.27

22 Same HMI for Operators Integrated DCS-ESD graphic windows and Navigator Page.28

23 Same instruments Faceplates except for the color of the Logo.. ;) Page.29

24 Same Alarms window and operation Different folders for DCS and ESD Page.30

25 Same Hardware diagnostic SCS Status Display - Node/ Module status - Database info. - CPU scan period - CPU loading - Communication loading - SCS operating mode - SCS security level - Number of forcing - Temperature status - Battery status etc. Page.31

26 Integrated SOE SOE resolution 1ms Date & Time Tag name Description Value In yellow trip event information Page.32

27 ESD Engineering Segregation Engineering IEC Function Block Diagram, Ladder Diagram, Structured Text System & I/O configuration Test (Simulator on PC) Self documentation Version Control Declare the variable to be shared with the DCS Page.33

28 But Integrated The standard Centum builder (System View) adds SCS to the system. ProSafe-RS SENG creates a Prosafe-RS tag list available for CentumVP. CentumVP ENG equalizes the tag list from SCS stations. Page.35

29 Integrated Instrument Management PRM Server PST Scheduler Server PRM Client PST Scheduler Client Ethernet SENG ENG HIS HART Multiplexer Vnet/IP(Control Network) ESD Valves VIP (VigilantPlant Integration Partner) Launched since February Dresser Flowserve Metso Samson

30 Integrated YARA Italia. 37

31 DCS-ESD integrated in global network

32 DCS-ESD integrated in global network Tot. 17 DCS/ESD controllers

33 Customization for each SIF «Ritengo che un punto di forza del lavoro sia stata l'interfaccia delle SIF implementate sulle HIS. Le informazioni che gli operatori hanno a disposizione è praticamente totale, e la semplicità dell'interfaccia sviluppata è tale da rendere quasi superflua la documentazione cartacea sull' implementazione della logica e le soglie di blocco, un vero valore aggiunto.» Initiators POS (by HW input coming from real key) MOS (by HW input coming from real key) 40

34 Conclusions 41

35 Key Features of ProSafe-RS Safety layer allows granting safe communication (TÜV certified) among safety controllers SIL 3 level protection in single configuration Easy and powerfull integration with DCS SOE, alarms, trends, HMI, PST,.. IEC 61508/61511 ISA S IEC EN298 (Bms) EN54-2 (F&G) G3 Ansi/ISA S71.04 Page.42

36 ProSafe-RS Installation Map 44

37 Thank you for your time Any question? 45