ff sis - stavanger november 2008
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FF-SIS
2008 Fieldbus Foundation
Fieldbus FoundationSafety Fieldbus for Process Automation FF
SIS (SIF)
Trygve Harvei
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FF-SIS
2008 Fieldbus Foundation
ABB Corporate Research CenterResearch 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
ProcessAutomation
AutomationProducts
RoboticsPowerSystems
PowerProducts
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FF-SIS
2008 Fieldbus Foundation
What do we need to ensure with safe communication?
Communication:
We must know that the values of the data we receiveis right
We must know that the data is not too old
We must know that the data is received from the rightnode to the right node
This is the purpose of the layered protocolssuch as TCP/IP or others?
Yes, but the probability calculations for errors is notgood enough
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FF-SIS
2008 Fieldbus Foundation
Some Industrial Safety Protocols
CIP-Safety
DeviceNet
Ethernet/IP
PROFIsafe PROFIBUS DP/PA
PROFINET
FF-SIS
FF H1
Vendor specific
ABB (Ethernet)
Hima (Ethernet)
PILZ Others
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FF-SIS
2008 Fieldbus Foundation
Motion Control and Safety
Source: ARC
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FF-SIS
2008 Fieldbus Foundation
Safety Measures in safety protocols
Trans-
mission
error
Number
sequence
Time
stamp
Receipt
acknow-ledge-ment
Identifier for
sender &receiver withwatchdogtimeout
Data
integrityassurance(CRC)
Redun-
dancywithcrosscheck
Different data
integrityassurancesystems forsafety & standardmessages
Messagerepetition
Loss ofmessage Messageinsertion
Sequencefailure
Datacorruption
SBonly
Delay
Masquerade
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FF-SIS
2008 Fieldbus Foundation
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
ESD: emergency shutdown systemSIS: safety interlock (or instrumented)systemBMS: burner management system
F&G: fire and gas system
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FF-SIS
2008 Fieldbus Foundation
Foundation Fieldbus extension - FF SIS
scope
SafetyInstrumentedSystems
n Extends FF Technology to Safety Instrumented
Systemsn Based on the IEC 61508 International Standard.n Example Application Areas:
Burner Management Systems Fire & Gas (petrochemical) Fuel Engineering
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FF-SIS
2008 Fieldbus Foundation
International Development Team
ABB AS NorwayABB Instrumentation ItalyBIFFI ItalyE.I. DuPont de Nemours, Inc. USAExxonMobil Research & Engineering USEEmerson Process Management USAFlowserve USAHIMA GermanyHoneywell SMS The Netherlands
ice-PROS CanadaInfraserv Hchst Technik GmbH & Co. KG GermanyInvensys/Triconex USAMetso Automation FinlandRockwell Automation USARotork Control Systems UKSaudi Aramco Saudi ArabiaSmar Brazil and SingaporeShell Global Solutions The Netherlands
Softing AG GermanyTV GermanyWestlock Controls Corporation USAYokogawa Electric Corporation JapanYokogawa - SCE The NetherlandsYokogawa UK Limited UK
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FF-SIS
2008 Fieldbus Foundation
FF-SIS Scope
n Extends FF Technology to SafetyInstrumented Systems
n Based on the IEC 61508 InternationalStandard.
n Example Application Areas:
Burner Management Systems Fire & Gas Fuel Engineering
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FF-SIS
2008 Fieldbus Foundation
FF-SIS End User Requirements
n Reduced Total Cost of Ownership for FF-SIS
applications.
CAPEX Hardware, Footprint, Commissioning, Power Consumption
OPEX Advanced diagnostics, Reduced test interval via increased DCF.
n SIL 2 and 3 applications
n Password protected access to FF-SIS field devices
n Additional Function Blocks (e.g. logic, 2 out of 3
voting)
n Definable actions on diagnosed failures trip,
message
n Handle discrete signals (e.g. switches, motor trips,
lights, push buttons, etc.) where H1 dynamic
performance is acceptable
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FF-SIS
2008 Fieldbus Foundation
FF-SIS End User Requirements
n Total system approach Total Asset Management FF-SIS and Non-SIS
Modular Logic Solvercentralized and distributedoption
Diagnostics Hybrid system architecture FF-SIS & 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
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FF-SIS
2008 Fieldbus Foundation
FF-SIS Extension Areas
n Communication
Meet IEC 61508 part 2 clause 7.4.8Communication Diagnostics
n User Application
Meet IEC 61508 part 3 clause 7.4.4Function Block DiagnosticsCRC on Device Description Files
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FF-SIS
2008 Fieldbus Foundation
Process Safety Time/
Safety Function Response Time
Stale counter must be applied in accordance with the specific application
3x communcation timeout as thumb rule
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FF-SIS
2008 Fieldbus Foundation
FF Scheduling of communciation and FB execution
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FF-SIS
2008 Fieldbus Foundation
FF H1- Slow but accurate & safe?The PID control algorithm
depend on the sampling of
process values + filtering
Polled approach PLC cyclic IO Copy
Jitter + drift
introduces I&D-errors
Synchronizedapproach
FF -In loop execution of
sampling and controlalgorithm
The analog SIS voter can rely
on fresh values -> best
possible Process Safety
Time
1 ms synchaccuracy
Alarm
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FF-SIS
2008 Fieldbus Foundation
FF-SIS Communication Extensions
n Black Channel Approach H1 Communication System (Black Channel) is unchanged.
A new FF-SIS protocol above the Black Channel detects networkfaults and appropriate action is taken without human intervention.
IEC 61508
IEC 61508
Black Channel
New FF-SISCommunication Diagnostics
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FF-SIS
2008 Fieldbus Foundation
FF-SIS User Application Extensions
n User Application New Function Blocks for FF-SIS Applications FBAP Part 6
New FBAP diagnostics detect application faults and appropriateaction is taken without human intervention.
IEC 61508
IEC 61508
Black Channel
New FF-SIS Function Blocks&Function Block Diagnostics
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FF-SIS
2008 Fieldbus Foundation
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
FF-SIS Diagnostics and Statistics added to device Resource Block
FF-SIS User Application Extensions
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FF-SIS
2008 Fieldbus Foundation
Operation Engineering
Proprietary Network
SIS Logic
Hardwired
Todays Proprietary SIS
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FF-SIS
2008 Fieldbus Foundation
EthernetSwitch
Operation Engineering
Proprietary Network
SIS Logic
Hardwired
H1
Operation Engineering
Total Asset
Management
HSE
FF-SIS Devices
Tomorrows Open FF-SIS
LinkingDevice
H1
Non-SIS FF Devices
LinkingDevice
. . . .Logic Solver?
Logic Solver
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FF-SIS
2008 Fieldbus Foundation
Control Network
Control/PLC
Seriell kommunikasjon/felt buss
Firewall
Plant Network / Intranett
Applicationserver
Aspectserver
Client/server Network
Tredje partapplikasjonserver
ArbeidsstasjonerEnterprise OptimizationSuite
MobileOperator
Connectivityserver
EngineeringArbeidsstasjoner
F&G SIL 2ESD SIL 3 PSD SIL2
System topology for process safety
Trenger sikker (safe) kommunikasjon pKontrollnetverks-niv og p felt-niv.
Delevis p operatr-niv
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FF-SIS
2008 Fieldbus Foundation
Increased diagnostic coverage with FF-SIS
The instruments and actuators
are included in the safety systemand becomes part of the
diagnostic testing
The increased diagnosticcoverage
Makes it possible to at an earlystage do repair in many cases
No longer proven in usecertification
TV will not accept the proven inuse concept for FF-SIS devices
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FF-SIS
2008 Fieldbus Foundation
Effects of increased diagnostic coverage
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FF-SIS
2008 Fieldbus Foundation
SIS_DI
SIS_AVTR
SIS_DO
Write Lock
S
SIS_WL
SIS_AI
SIS_RB
SIS_WL
SIS_AI
SIS_RB
SIS_WL SIS_AISIS_RB
SIS_WL
SIS_RB
Example FF-SIS Application
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FF-SIS
2008 Fieldbus Foundation
SIS_DI
SIS_DVTR
SIS_DO
Write Lock
S
SIS_WL
SIS_DI
SIS_RB
SIS_WL
SIS_DI
SIS_RB
SIS_WL SIS_DISIS_RB
SIS_WL
SIS_RB
Example FF-SIS Application
PS PS PS
SIS_LOGIC
SIS_WL
SIS_DI
SIS_RB
Estop
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FF-SIS
2008 Fieldbus Foundation
USER LAYER
TRANSPORT LAYER
SESSION LAYER
PRESENTATION LAYER
APPLICATION LAYER
PHYSICAL LAYER
DATA LINK LAYER
NETWORK LAYER
1
2
3
4
5
6
7
OSI Model
PHYSICAL LAYER 1
2
3
4
5
6
7
COMMUNICATIONSTACK
IEC 61158@ 31.25 kbit/s
IEC 61158 - DLL
IEC 61158 - FMS
H1
USER LAYERDD IEC 61804-2
IETF TCP/UDP
IEEE 802.3MAC
IETF IP
IEC 61158 - FDA
IEEE 802.3u@ 100 Mbit/s
HSE
USER LAYERDD IEC 61804-2
FF-SIS New Kid on the Block
PHYSICAL LAYER
COMMUNICATIONSTACK
H1/HSE
USER LAYERDD IEC 61804-2
FF-SISIEC 61508
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FF-SIS
2008 Fieldbus Foundation
Target Schedule
2002 4Q FF Board of Director Approval for SIS Project
2003 1Q Project Kickoff Meeting 2Q Architecture Completed 3Q Draft Preliminary Specifications (DPS) Version 0.4 4Q TV Concept Approval for SIS
2004 1Q 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 Testing @ Infraserve inFrankfurt
2005 Release SIS Specification 1.0 and Final TV Type Approval
2008 FF SIS Rollout Team
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FF-SIS
FF SIS demonstrators - SROT