prosafe rs introduction
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Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
1
Product Details March 1, 2005 MK, Industrial Safety Systems Dept.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 2
The name, “ProSafe” has been Yokogawa’s brand in the safety market over many years. “ProSafe” is a mix word of “Professional” and “Safety”. We offer the know-how and expertise for plant safety.“RS” is a newly added abbreviation of “Responsive Solutions”.ProSafe-RS is named to provide the best answer for evolving safety environment as a total, integrated solutions for process industries.
ProSafe-RS product name
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 3
ProSafe-RS product color The color gives active image of “safety” and expresses our willingness to provide thebest safety solutions to customers.
Name of color: Terracotta Orange
Background of choosing the color:
Orange represents vitality. The color stands out and gives a ‘signal’ to people.
Orange has a image of positiveness. It represents that we are willing to play active role in calling customers’ attention for safety. Customers can easily recognize our product even from afar.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation Page 4 Confidenti
al
ProSafe-RS Projects by Country
Over 300 projects from 50 Over 300 projects from 50 countries!!countries!!
Feb. 2005 - Apr. 2008Feb. 2005 - Apr. 2008
Algeria China Italy Netherlands SudanAngola Congo Japan Nigeria TaiwanAustralia Egypt Kazakstan Oman ThailandAustria France Korea Pakistan TurkeyBelgium Germany KSA Philippine UAEBrazil Hungary Kuwait Qatar UKBrunei India Macedonia Romania UkraineBulgaria IndonesiaMalaysia Russia USACanada Iran Mexico Singapore VietnamChili Iraq Morocco Spain Yemen
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 5
Key messages to customers
ProSafe-RS is Yokogawa’s own product backed by field- proven CENTUM CS3000 technology and long years of experience in safety system.ProSafe-RS offers - Truly integrated system of DCS and SIS - Safety and high availability in a simple architectureProSafe-RS aims not only the integration of SIS to DCS, but also our consistent business frame “from sales to service & support”.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 6
Backed by CENTUM CS 3000 technology “Pair & Spare” CPU Redundant CPU module & I/O module Redundant network
from control highway to data bus in a module
V net
Field-proven CS3000 technology
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 7
Product BU, Cover
A revolution in Safety Instrumented System
Expanding the Safety Spectrum ProSafe-RS offers something more beyond conventional ESD (emergency shutdown) system.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 8
Product BU, traditional DCS-SISProSafe-RS
- Integrated plant safety
Traditionally, DCS and SIS had been two separate systems, because they were built differently by separate vendors.We required separate- design- human-machine interface - manner for maintenance and - additional work to connect both systems, etc.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 9
Product BU, Overall features The world’s first truly
integrated safety controller
ProSafe-RS is certified SIS as SIL3 by TÜV in the integrated configuration.ProSafe-RS is integrated directly to V net of CENTUM CS3000. ProSafe-RS offers plant safety, availability, efficiency without compromise.
Functional Safety mark of TUV Rhineland
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 10
Easy System Design -> No gateway / interface module is needed
for DCS-SIS Data Exchange.-> No separate layout and communication design
is needed for DCS system & SIS system.Ethernet
CS 3000 Eng. Safety system Eng.
V net
CS 3000 HIS
CS 3000 FCSSafety Controller
Product BU, one network
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 11
Product BU, Overall features The world’s first truly
integrated safety controller
Benefits of integration:- Faster project implementation by one network, - Greater operational efficiency by one window, - Lower cost of ownership by one solution. Advantages in terms of SIS selection and configuration:- Simple choice by Single SIL3, - Availability by redundancy.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 12
Product BU, One process : one network, one window
One process : one network, one window
V net supports safety-related communications which has been certified by TÜV. It ensures the logical segregation of DCS and SIS.This breakthrough is the first for the process control world. The integrated DCS and SIS system can eliminate separate monitors for two systems.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 13
Product BU, One process : one network, one window
One network
requires no gateway or interface hardware for data exchange between SIS and DCS functions.eliminates the need to install a dedicated safety network.offers much simpler and quicker route to system realization without complex engineering effort for integration.reduces maintenance cost. lowering total manpower on large process plants.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 14
Data exchange between Safety controllers
V net
CS 3000 HIS
CS 3000 FCSSafety Controller
Safetycommunication
-> Safety Communication is available on Vnet.(Yokogawa original safety protocol, TUV certified)
No affect to safety comm.
Product BU, one network
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 15
Data access to Safety Controller
V net
CS 3000 HIS
CS 3000 FCSSafety Controller
Safety Data to FCS
-> No interface module is required.
Product BU, one network
Tag access
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 16
V net
CS 3000 FCSCPU node
Product BU, one network
CS 3000 HIS is V net
Timemaster
Time Synchronization by Standard V net function
GPS as an option (IRIG interface on SCS)
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 17
Merits of Common ArchitectureStandard design of cabinet layoutStandard way of Hardware replacement
FIO
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation ProSafe-RS R1.02 18
System configuration with HART module
FFCS-L
Vnet/IP
PRMHIS/ENGS
1BUS2BUS
FFCS-L
Vnet/IP
PRMHIS/ENGS
1BUS2BUS
Vnet
SENG
SENG
Vnet router
Before R1.02.00
HART Multiplexer
SCS
SCS
After R1.02.00
HART Safety Sensor
HART Equipment
HART signal go though ProSafe-RS
Without any HART devices.
HART signal
HART signalbetween MUX and
PRMvia Serial Communic
ation
HART signal
HART signal
SafetyValves
ControlValves
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation ProSafe-RS R1.02 19
[Example]Maximum 5km in total.
Maximum 9 I/O node can be connected.
Fiber-optic cable Connector:
LC type (IEC60754-20 compliant) Recommended cable: Silica-Based Single-Mode Fiber(JISC6835 SSMA -9.3/125,IEC60793-2-50B1.1)
CPU node(SSC10□/50 □)
I/O node(SNB10D)
SNB10D: Max. 9 units
ESB Bus
ESB Bus
Possible to install I/O node at remote locations via fiber-optic cable.
Fiber-optic cable (4 cables)
I/O node(SNB10D)
I/O node(SNB10D)
Optical ESB Bus Repeater
V-net
ESB Bus
Mounting unit dedicated for optical modules
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 20
Product BU, One process : one network, one window
One window
provides the same environment to monitor SIS and DCS in accustomed way.eases comparison of the control data and the safety data, as well as alarms for quick decision making.improves back-tracking analysis of integrated events.… one solutionreduces the time and cost required to total process safety.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 21
Tag access from HIS to DCS data and SCS data Integrated monitoring on HIS
V net
CS 3000 FCSProSafe-RS SCS
CS 3000 HIS
Product BU, One window
Integrated Monitoring - Faceplate - Trend - Graphic - System status - Alarm - SOE
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation ProSafe-RS R1.02 22
Enhancements of CS 3000 Integration
New Safety Function for Manual Operation from HIS– Manual operation of a valve from HIS– Manual Reset PB from HIS– Manual operation and monitoring for
an analog output (4 to 20 mA) – * Safety functions certified by TUV
= Integrated functions with CS3000 is also included TUV Certification.
Support some functions same as CS3000 – Alarm suppression on HIS– User defined alarm processing levels– Plant hierarchy
*New version of CS3000 R3.08 is coming.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 23
System status Product BU, One window
SCS FCS
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 24
Process alarm
ProSafe-RS
All of CS3000 and ProSafe-RS
Product BU, One window
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 25
System Alarm
ProSafe-RS
All of CS3000 and ProSafe-RS
Product BU, One window
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 26
1ms resolution
・ Time & Date・ Event name ・ Comment・ Data
Product BU, One window
Yellow shows the trip event
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 27
Product BU, Simple solutions are always best
A single, simple, SIL3 solutionYokogawa’s state-of-the-art design miniaturizes SIS. Each single module (processor, input or output) is SIL3 rated featuring a dual architecture and extremely high diagnostic coverage factor of more than 99%.This architecture is simple to understand, design, install and maintain SIS.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 28
SIL3 will be achieved in single Input-CPU-Output module configuration
- all redundant in a module using proven “Pair & Spare” CPU from CS3000 scheme
Single CPU module
Single Input module Single Output module
InputCircuit, MPU
Circuit, MPU
CPUMPU, memory
MPU, memory
OutputCircuit, MPU
Circuit, MPU
Product BU, single, simple, SIL3
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 29
Product BU, Simple solutions are always best
Plug-in availabilityDual redundant module configuration for higher system availability and fault tolerance with no effect on SIL3. Redundant configuration is selectable part by part, such as redundant processor modules with single input and single output, or a single input and redundant output. This flexibility provides a combination of safety and economy.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 30
High availability will be reached by redundant module options of CPU module & I/O module.
- Proven redundant technology from CS3000 - Redundant options are selectable part by part!
Redundant CPU module
Redundant Input module
Redundant Output module
InputCircuit, MPU
Circuit, MPU
CPUMPU, memory
MPU, memory
OutputCircuit, MPU
Circuit, MPU
InputCircuit, MPU
Circuit, MPU
CPUMPU, memory
MPU, memory
OutputCircuit, MPU
Circuit, MPU
Product BU, Plug-in availability
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 31
Module redundancy is for availability, not for safety.
System is still SIL3 if all of one side are fail.
InputCircuit, MPU
Circuit, MPU
CPUMPU, memory
MPU, memory
OutputCircuit, MPU
Circuit, MPU
InputCircuit, MPU
Circuit, MPU
CPUMPU, memory
MPU, memory
OutputCircuit, MPU
Circuit, MPU
Product BU, Plug-in availability
××
×
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 32
Product BU, Highly scalable architectureProSafe-RS employs the same flexible and scalable hardware standards as the CS3000.ProSafe-RS system can be as small as one rack with power supply, processor, and up to around 100 I/O channels.System with a (pair of) powerful processor module can also be extend to support around 1000 I/O points.ProSafe-RS can be distributed which will support up to 64 stations in just one domain.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 33
*Target scan time
50 I/Os in a CPU rack
* 50ms for 50 DIO points
1000 I/Os for a CPU rack and I/O racks
* 250ms for 1000 IO points
Total 10 racks(1000 points)
Distribution on Vnet 64 stations in a domain, 100 thousand tags
V net
Very Small
Large & distributed
Product BU, Highly scalable architecture
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 34
DCS and SIS share the Vnet components (repeater/bus converter/gateway)
DCS and SIS are integrated physically, segregated logically.
Ethernet
BCV
Repeater
CGW
ENG HIS
CGW
SENG
OpticalRepeater
VnetDomain A
SafetyController Vnet
Domain B
VnetDomain C
OpticalRepeater
FCS
FCS
FCS
SafetyENG
HIS/ENG
SENG
FCSSafetyController
SafetyController Safety
ControllerSafety
Controller
SafetyController
FCS
Product BU, Highly scalable architecture
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 35
Product BU, A breakthrough in size reduction
ProSafe-RS provides a breakthrough in SIS footprint and cabinet size comparing with traditional safety PLCs. These benefits are for all users, but particularly for any application where space or weight is at a premium such as - offshore platform or - remote equipment stations.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 36
Product BU, A breakthrough in size reduction
Upper blue area mentions about engineering with IEC 61131-3.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 37
Engineering tools IEC 61131-3 Function Block Diagram & Ladder
DiagramSystem & I/O configurationTest (Simulator on PC / Real target)Self documentationVersion Control
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 38
Monitoring/Maintenance on Eng PCLogic status displaySystem status display & Diagnostic dialog
viewerSOE viewerForcing variables (Input, Output, Logic variables) Online partial logic modification (TUV to be
certified)
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 39
Product BU, VigilantPlant
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 40
Product BU, Solutions for the safety environment
The growing influence of functional safety standards (IEC 61508/61511, ANSI/ISA S84) are forcing processing companies to adopt.Yokogawa's commitment to IEC 61508 - combined with the intrinsic simplicity of ProSafe-RS provides the ideal platform to support this trend. Both ProSafe-RS and the Yokogawa organization have been certified to be in compliance with IEC 61508/61511.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 41
Product BU, Solutions for the safety environment
These area mentions about our history, current products and support for them.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 42
Product BU, Solutions for the safety environment
This network configuration is available. Control domain and safety domain integrated with BCV are also available.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 44
Integration BU, Features of ProSafe-RS
1. Meeting Safety StandardsThe safety standards IEC 61508 and 61511 that have world-wide recognition require precise safety requirements for process plants.Both the ProSafe-RS product and the YOKOGAWA organization have been certified by TÜV to be in compliance with IEC 61508 and 61511. ProSafe-RS is certified as SIL 3 in a single module configuration.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 45
Integration BU, Features of ProSafe-RS
2. High Degree of System AvailabilityWhile realizing SIL 3 capability on a single module, the CPU and I/O modules of ProSafe-RS can have dual-redundant configuration. This set-up drastically prevents unexpected plant shutdowns.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 46
Integration BU, Features of ProSafe-RS
3. Highly Scaleable ArchitectureProSafe-RS employs the same flexible architecture of CENTUM CS 3000 R3, allowing SIS functions to be configured for any size of application. ProSafe-RS can also meet configuration requirements including centralized and distributed systems.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 47
Integration BU, Example windowsControl Window : Control data from FCS and safety data from SCS can be monitored in a single window.Alarm Window : Alarms for both FCS and SCS are shown in the single Alarm Window. Operators can divide the window to show the alarm from SCS in the upper section and all of the alarms in the lower section.Tends
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 48
VigilantPlant BU, Cover
Integrated Plant Safety Managementfor Alert Manufactures
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 49
Integrated Plant Safety ManagementSafe plants call for more than emergency shutdown. Let’s look at the big picture.
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 50
SEE CLEARLY
A Recurrent Ailment...
...and a Vigilant Remedy
Heavy operator workload by recurrent alarms
Alarm flooding going unattended:-Causes oversights, delays, and incorrect operations -Leads to unnecessary plant shutdown
Operators are able to focus on critical alarms and predictive alerts
AAASuite advanced alarm administrator:-Suppresses nuisance alarms automatically -Add and highlight value-adding alarms for quick and effective decision making
BEFORE AFTER
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 51
KNOW IN ADVANCE
Protect Reactively, Analyze Retrospectively...
...or Predict, Avoid, and Minimize EmergencyReactive protection, with
little help to operators and little synergy with DCS
Conventional ESD system:- Dedicated human machine interface / network / database- Analyze events retrospectively, but realtime information for operator is cumbersome, slow, and limited
Seamless monitoring of safety data enables prediction of critical conditions
ProSafe-RS Safety Controller- Common HMI and unified event data for integrated safety management- Alerts operators of critical conditions before they reach emergency- Ensures SIL3 protection in case the process reaches emergency conditions
AFTERBEFORE
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 52
ACT WITH AGILITY
Re-start-up is an intensive non-routine operation under extreme pressure
The ad-hoc approach:-A large amount of manual operations that demand extra care for timing and attention to detail
Scrambled Efforts...
...or Orderly Teamwork
Non-routine but smooth and reliable operation by navigator
Exapilot advanced operation navigator:-Interactive and graphical software for non-routine operational procedure-Assists interaction intensive procedure-Leverages accumulated know-how of experienced operators & engineers
BEFORE AFTER
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 53
VigilantPlant BU, END
Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 54
Thank you for your attention.
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