[ppt]powerpoint-presentation - abb group · web viewmaking the plant site a safe environment...
TRANSCRIPT
© 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 Group May 6, 2023 | Slide 2
© ABB GroupMay 6, 2023 | Slide 3
Process Safety Market is growingRespond to energy demand at reduced production risk
© ABB GroupMay 6, 2023 | Slide 5
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
© ABB GroupMay 6, 2023 | Slide 6
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…
© ABB GroupMay 6, 2023 | Slide 8
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
© ABB Group May 6, 2023 | Slide 9
© ABB Group May 6, 2023 | Slide 10
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...”
© ABB Group May 6, 2023 | Slide 11
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
© ABB Group May 6, 2023 | Slide 13
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
© ABB Group May 6, 2023 | Slide 14
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
© ABB Group May 6, 2023 | Slide 15
© ABB Group May 6, 2023 | Slide 16
What is the scope of TÜV Certification?800xA High Integrity – ABB Safety Certificates
Product Safety Certificate
Development Department Safety Certificate
Safety Manual
© ABB GroupMay 6, 2023 | Slide 17
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
© ABB Group May 6, 2023 | Slide 18
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
© ABB GroupMay 6, 2023 | Slide 19
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
© ABB Group May 6, 2023 | Slide 20
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
© ABB Group May 6, 2023 | Slide 21
Process Operator
Safety Operator
Process Engineer
Safety Engineer
Operate BPCS X X
Operate SIS X
Engineer BPCS X X
Engineer SIS X
© ABB Group May 6, 2023 | Slide 22
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
© ABB Group May 6, 2023 | Slide 23
© ABB Group May 6, 2023 | Slide 24
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
© ABB Group May 6, 2023 | Slide 25
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...”
© ABB Group May 6, 2023 | Slide 26
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
© ABB Group May 6, 2023 | Slide 28
Questions & Answers
© ABB Inc. May 6, 2023 | Slide 29
© ABB Group May 6, 2023 | Slide 30