systems approach to system integration - using industrial ... · pdf fileasas cs cs router...

© ABB Group April 27, 2012 | Slide 1

Systems Approach to System Integration - using Industrial Ethernet as an enabler Ifea, Brann-, Gas-, og Nødavstegningssystemer Systemintegrasjon Bergen 2011-05-11, Jon Klakeg / ABB AS, [email protected]



Systemintegrasjon

1. SAS / ICSS Generelt

System Topologier

Basis funksjoner

Informasjonsflyt

2. Integrasjon

3 parts pakker / systemer

Telecom

3. Industrielt Ethernet

IEC 61850

Profinet

4. Kommunikasjon i sikkerhetssystemer

Standarder

Profisafe PA

SIS Foundation Fieldbus (FF)

IO Topology


Local monitoring & Subsystem Engineering

Asset Monitoring & IO Asset Monitoring & IO

Security features

Engineering

(nnView

nnConfig)

SAS Topology – Sample Generic FPSO

SAS Topology Sample – Peregrino Field Development Multi System Integration

Process

AS

CS

Router

Safety

CAP IMS

CCR

AS

CS

Router

Process

AS

CS

RAS

Router

FPSO (Subscriber System) WHP1 (Provider System)

Operator Workstations Engineering

Safety

CAP

CAP

Plant Network

IMS

IMS

Process

AS

CS

Router

WHP2 (Provider System)

Safety

CAP IMS

Sub system 3 -9: Future Provider4 Systems

RAS

Safety Process

Closed loop control

SIL rated communication

Fast load shedding

Process

Model Simulator

OS OS OS OS

OS OS OS OS

Operator Work stn

Onshore

Instructor Training

IMS

Office Systems

Aspect Objects – Keeps information together...

Quality

report

Cost of

operation

Production

report

Operator

Graphics

Control

Maintenance Record

Simulation

Functional

Description

Logics

Maintenance list

Data sheet Faceplate

Orderform

Drawing

Integrated System Environment


Aspect

Object

Real

Object Faceplate

Aspects

Control

Graphics

Report

Trend

Applications

Control

Builder

Active

Graphics

Reports

Trends

Aspect Systems

The Aspect Object Architecture

Provides an integration of third party

controllers and PLCs

PLC Connect (1oo2 redundancy)

Modbus

RTU

Comli

SattBus Dial-up

IEC870

OPC DA 2.0 server

Control Network

Provides the following features:

Basic object types for PLC type signals and

softpoint signals

Configuration tools for creating and editing

PLC type objects

A full set of faceplates for PLC type objects

Integrated RTDB (Real Time DataBase) to

keep an updated image of connected process

points as well as calculated softpoints

Communication drivers

Dial Manager for remote communication

Alarms detection and OPC Alarms and Events

generation for PLC binary signals

Alarms limit detection and OPC Alarms and

Events generation for PLC integer and real

signals

Open interface to PLC signals and softpoints

from application programs in VB and C++

PLC Connect

Telecom

ICSS Integration of Telecom System

GENERAL:

1. Network is part of LAN system

2. All voice circuits are integrated

3. All communication over IP GBIT

NOTES:

1. Duplicated IP-rout, Fiber and Radio Link

2. Can be duplicated

3. PAGA will have a backup station - CAP

LEGEND:

LAN/WAN

Onshore

Management

Terminal Management

Server Media

Server

Telecom Equipment Room

UHF

System

(Option)

PA/A

System

PA/B

System

PABX

System

GMDSS/DSC

System

VHF/FM

System

VHF/AM

System

NDB

Remote Control

Note 1

Local - CCR Collaboration Room /ERR Hospital Reception

= Operator Control Panel

= Media Interface

Central Equipment

Note 2

Note 3

TMS

System

OPC

Server

SAS System

CCTV

System

Telecom Integration - CCTV


Telecom Integration - CCTV Data types

Process Image – cyclic/fast data (horizontal)

Parameter access – acyclic data (vertical)

Startup parameters (in engineering tool

like CBM)

Runtime parameters available,

”descriptor battle” ongoing

Events with timestamp from device

Have severity but no state, need

clarification

Bulk data

Arrays or files with information to be

further analyzed in specialized tools after

transfer to backend system


Telecom Integration - IR Camera Object


IO Topology


Asset Monitoring & IO

Engineering

(nnView

nnConfig)

Industrial Ethernet - What is the driver? (connectivity)


SPA ZC

Modbus MUX

Remote IO & Cabling

Modulebus

Modbus/RTU

61850 PROFINET

PROFIBUS

Drivebus

LON

-103

-104

Then

Now

Common Approach on Industrial Ethernet

Control

•Time

•Process Values (DI, AI)

•Events & Alarms (local

time tag)

•Commands

•Disturbance Data

•Device Parameters

MV Ctrl & Prot Drives LV Ctrl & Prot

Remote Link

i.e. NCC

•Time



time tag)

•Commands

•Disturbance Data


•Time



time tag)

•Disturbance Data


•Time



time tag)

•Equipment statistics

•Equipment diagnostics

…

•Process Values (AI, DI)

•Commands, Object Select/Lock, Interlocking

•Time Sync

•(Raw AI samples for Distributed Busbar protection and synchro-check)

… … …

HV Ctrl & Prot

…

Asset Mgmt/

Maintenance Process Eng. Operator

Open standards as basis for integration

Simplify engineering & life

cycle management

Meet ”axiom” requirements

of electrical systems

Fast communication for

control

Local time stamp in device

Access to device

information to support all life

cycles

Efficient transfer of bulk

data


The word "axiom" comes from the Greek word ἀξίωμα (axioma), a verbal noun from the verb ἀξιόειν (axioein), meaning "to deem worthy",

but also "to require", which in turn comes from ἄξιος (axios), meaning "being in balance", and hence "having (the same) value (as)",

"worthy", "proper". Among the ancient Greek philosophers an axiom was a claim which could be seen to be true without any need for

proof.

Use device integration

technologies such as XML

based descriptions

Support for network based

communication, enabling a

common infrastructure for

most functions

Interoperability to support

vendor independent

extensions

http://en.wikipedia.org/wiki/Greek_language

http://en.wikipedia.org/wiki/Verbal_noun

http://en.wikipedia.org/wiki/Ancient_Greece

http://en.wikipedia.org/wiki/Philosopher


Asset management & tools, 800xA and Electricals

MV Drives

Proxies

to other

buses

Fieldbus Network

HV/MV LV

Switchgear

LV

Products

Drives Remote I/O Instrumentation

IEC 61850 PROFINET FF H1

Device Tool

Framework

Visualization (Operator)

Asset Monitors CMMS - Work orders

Device Management

Diagnostics

Device

Diagnostics

Integration of information example, added value


Basic information availability from ”devices” using IEC 61850 and PROFINET

Data types

Process Image – cyclic/fast data (horizontal)

Parameter access – acyclic data (vertical)

Startup parameters (in engineering tool

like CBM)

Runtime parameters available,

”descriptor battle” ongoing

Events with timestamp from device

Have severity but no state, need

clarification

Bulk data

Arrays or files with information to be

further analyzed in specialized tools after

transfer to backend system © ABB Group April 27, 2012 | Slide 26

Parameter sets

Intelligent tools

Structured data

Profile based

XML descriptors



IEC 61850

IEC 61850 is a standard for the design of electrical

Substation Automation.


Conventional approach Electrical & Automation System

Copper-wired inter-bay signals like: protection blocking, control interlocking…

Interlocking, shared voltage signals…

Monitoring, control

Station bus (e.g. Modbus RTU)

External signals

CI 854

Remote

I/O

Client/Server network

Connectivity / Aspect

Servers with IEC

conventional connection

Engineer

Workstation

Color Laser

Printer

Color Laser

Printer

ABB DCS


IEC61850 approach Electrical & Automation System.

External signals

Remote

I/O

Client/Server network

Connectivity / Aspect

Servers with IEC

conventional connection

Engineer

Workstation

Color Laser

Printer

ABB DCS

Monitoring, control, settings

Interlocking, shared external signals

Time synchronization

ESD

SIGNALs

CI 868

IEC 61850

Engineer

Workstation


Electrical Systems - Integration

../fpso/Saipem/Electrical Control Typicals.pdf



Introducing PROFINET – simplifying fieldbusses PROFINET is based on the standard Ethernet used

in offices and IT departments

Utilizes modern Ethernet features that is

needed for real time operation and control

Support for “all media”

Suite of services for:

Time critical operation

Information integration

Time stamping & Clock sync

Key Benefits

Cost savings in integrated

system deliveries

Efficient device integration and system

level engineering

Utilizes common infrastructure with

multiple protocols -> coexistence

PROFINET for Process Automation


Device access

Horizontal communication on local network using Ethernet

frames

Vertical services (acyclic communication) using

client/server model on IP

Routable

Each device shall support minimum 3 clients

IEC 61850 connectivity server for client access

Object access (report control block)

Bulk data for trip analysis

PROFINET

Events routed through controller, attached to HW-

object if no ”AlarmCond” block

Demonstrator on parameter access via network (read

only) exists


Peer Peer

Client

Server

Standard Ethernet frame used for FAST communication

IEC 61850 GOOSE

Coexistence of multiple protocols in the same network

Fast horizontal communication

61850 GOOSE messages

PROFINET Cyclic messages

Both using Ethernet directly with

separate ”Ethertype”

Priority tagging


Using UDP/TCP IP

Alarming

Parameter read and write

Using Ethernet Discovery Protocols

PROFINET DCP for device discovery

and configuration

Monitoring & Funcitons

SNTP, SNMP, DHCP VLAN

QoS

Multicast

Filtering

Safety Communication within Oil & Gas

Safety for humans and

environment

Protection of electrical

supplies

Motor protection based

on current measurement

Robot and machine control

Petrochemical production control

Normal safety

level

High

safety level

Fire and Gas leak detection on

oil platforms

Process control

Control Network

Control/

PLC

Seriell kommunikasjon/felt buss

Firewall

Plant Network / Intranett

Application

server

Aspect

server

Client/server Network

Tredje part

applikasjon

server

Arbeidsstasjoner Enterprise Optimization

Suite

Mobile

Operator

Connectivity

server

Engineering

Arbeidsstasjoner

F&G SIL 2 ESD – SIL 3 PSD – SIL2

System topology for process safety

Trenger sikker (safe) kommunikasjon på

Kontrollnetverks-nivå og på felt-nivå.

Delevis på operatør-nivå

IEC 61508

"Functional safety of electrical/electronic/programmable

electronic safety-related systems".

IEC 61508 has the following views on risks:

zero risk can never be reached

safety must be considered from the beginning

non-tolerable risks must be reduced

Safety Standards (PROFISAFE ex.)

SIL - Safety Integrity Level, PL – Performance Level

Safety layers in Ethernet based Safety

MAC layer

IP layer

UDP layer

Prosess

Control

Spesific

Safety

application

MAC layer

IP layer

UDP layer

Prosess

Control

spesific

Safety

application

switch

safety layer safety layer

Tests the

critical

elements

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

Autronica

Others

Process Safety Time/ Safety Function Response Time

Stale counter – must be applied in accordance with the specific application

3x communication timeout as thumb rule

Grace time depends on the industry (typical figures)

Chemical + O&G: 1s Cement: 10s

Tilting train: 100ms X-by wire: 10ms Substations: 5 ms

Printing: 20 ms

TÜV processes

Certification

System solutions (typical setup tested and certified)

HW/SW

Product solution HW/SW

Functional Safety Management, organization certified

for doing safety development and production

Approval

Defined safety measures on specified architecture

Example: FF SIS specification approved

Safety Instrumented System (SIS)

PROFISAFE PA

PROFISAFE transparent to ”media”

FF SIS

Ambitious approach to SIS

Defines ”control in the field”

Function blocks for building safety applications

Shared with ”host”

Distributed

ESD: emergency shutdown system

SIS: safety interlock (or

instrumented) system

BMS: burner management system

F&G: fire and gas system

PROFISAFE

PROFIsafe was the first communication standard in compliance with IEC 61508, which permits standard and safety-related communications on one and the same bus. With SIL 3 (Safety Integrity Level), it fulfills the highest requirements in the process industries.

PROFIsafe utilizes the standard services of the lower-level bus system to implement safe communication. When transmitting messages, PROFIsafe comes up with four measures against any possible faults or errors such as corrupted addresses, loss, delay, etc.:

PROFIsafe uses existing standard communication components such as cables, ASICs and standard software packages.

With SIL 3 (Safety Integrity

Level), it fulfills the highest

requirements in the process

industries.

PROFISAFE PA

The PROFIBUS PA ring topology is connected to two redundant PROFIBUS DP segments of a controller via the redundant DP/PA coupler. Each of the maximum 8 Active Field Distributors (AFD – Siemens product) in this PROFIBUS PA ring with automatic bus termination has 4 short-circuit-proof spur lines for connection to devices.

As shown in the figure below, safety-related and fault-tolerant applications can be implemented with relatively low device and cable requirements. The configuration of the ring can also be changed during runtime. Even brief opening-up of the ring in order to integrate a further AFD is possible without production failures. The diagnostic integrated in the redundant couplers and the AFDs expand the existing possibilities for communication and cable diagnostics, and makes fault locating easier in the event of an open-circuit. The concept of Flexible Modular Redundancy is thus implemented down to the field level.

Security for PROFIsafe

Standard says:

Wireless example from PNO (PROFIsafe)

Foundation Fieldbus extension - FF SIS scope

Safety

Instrumented

Systems

n Extends FF Technology to Safety Instrumented Systems

n Based on the IEC 61508 International Standard.

n Example Application Areas:

Burner Management Systems

Fire & Gas (petrochemical)

Fuel Engineering

FF SIS -Specification developoment team -> 2005

International Development Team

ABB AS Norway

ABB Instrumentation Italy

BIFFI Italy

E.I. DuPont de Nemours, Inc. USA

ExxonMobil Research & Engineering USE

Emerson Process Management USA

Flowserve USA

HIMA Germany

Honeywell SMS The Netherlands

ice-PROS Canada

Infraserv Höchst Technik GmbH & Co. KG Germany

Invensys/Triconex USA

Metso Automation Finland

Rockwell Automation USA

Rotork Control Systems UK

Saudi Aramco Saudi Arabia

Smar Brazil and Singapore

Shell Global Solutions The Netherlands

Softing AG Germany

TÜV Germany

Westlock Controls Corporation USA

Yokogawa Electric Corporation Japan

Yokogawa - SCE The Netherlands

Yokogawa UK Limited UK

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

COMMUNICATION

STACK

IEC 61158

@ 31.25 kbit/s

IEC 61158 - DLL

IEC 61158 - FMS

H1

USER LAYER DD – IEC 61804-2

IETF TCP/UDP

IEEE 802.3

MAC

IETF IP

IEC 61158 - FDA

IEEE 802.3u

@ 100 Mbit/s

HSE


PHYSICAL LAYER

COMMUNICATION

STACK

H1/HSE


FF-SIS

IEC 61508

FF SIS – layered model

The FF SIS vision

Operation Engineering

Proprietary Network

SIS Logic

Hardwired

H1

Operation Engineering Total Asset

Management

HSE

FF-SIS Devices

Linking

Device

H1

Non-SIS FF Devices

Linking

Device

Ethernet

Switch

. . . .

Example FF SIS application

SIS_

DI

SIS_

AVTR

SIS_

DO

Write Lock

S

SIS_

WL

SIS_

AI

SIS_

RB

SIS_

WL

SIS_

AI

SIS_

RB

SIS_

WL

SIS_

AI

SIS_

RB

SIS_

WL

SIS_

RB

systems approach to system integration - using industrial ... · pdf fileasas cs cs router...

Documents