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© ABB Group June 4, 2012 | Slide 1
Riduzione del rischio con sistemi di automazione di sicurezza
Daniele Corali, ABB SpA – Process Automation Division
© ABB Group Febbraio 2012 | Slide 2
Leader globale nelle tecnologie per l’energia e l’automazioneLeader di mercato nei principali business
135.000 dipendenti in oltre 100 paesi
38 miliardi di dollari in ricavi (2011)
Nata nel 1988 dalla fusione di società di ingegneria svedesi e svizzere
Gruppi precursori fondati nel 1883 e nel 1891
Gruppo quotato in borsa con azionariato diffuso e sede principale in Svizzera
© ABB Group Febbraio 2012 | Slide 3
Power and productivity for a better worldLa nostra visione
ABB, uno dei principali gruppi di ingegneria a livello mondiale, aiuta i suoi clienti a utilizzare l’energia elettrica con efficienza, aumentare la produttività industriale e ridurre l’impatto ambientale in maniera sostenibile.
© ABB Group Febbraio 2012 | Slide 4
La nostra strutturaCinque divisioni globali
Power Products
Power Systems
Discrete Automation and Motion
ProcessAutomation
8,4 miliardi di dollari27.500
dipendenti
7,8 miliardi di dollari28.500
dipendenti
(Ricavi 2011)
Low Voltage Products
5 miliardi di dollari21.000
dipendenti
10,3 miliardi di dollari 35.000
dipendenti
7,7 miliardi di dollari19.500
dipendenti
Apparecchiature elettriche, automazione, sistemi di controllo e strumentazione per la generazione di energia e i processi industriali
Trasmissione di energia
Soluzioni per la distribuzione
Prodotti di bassa tensione
Motori e azionamenti
Sistemi per edifici intelligenti
Robot e sistemi robotizzati
Servizi per aumentare la produttività e affidabilità
Il portafoglio ABB comprende:
© ABB Group Febbraio 2012 | Slide 5
Energia e automazione sono ovunque intorno a noi Troverai la tecnologia ABB…
in orbita attorno alla terra o al lavoro in profondità,
attraverso gli oceani e sul fondo del mare,
nei campi in cui crescono i nostri raccolti e nei processi di confezionamento del cibo,
nei treni su cui viaggiamo e negli impianti che trattano la nostra acqua,
nelle centrali dove si genera la nostra energia e ovunque nelle nostre case.
© ABB Group Febbraio 2012 | Slide 6
Un contributo allo sviluppo tecnologico grazie all’innovazione All’avanguardia dal 1883Fondatori
1900
Robot industriale
Turbosoffiante
HVDC
Altissima tensione
Interruttore isolato in gas
Azionamenti motore a velocità variabile Sistemi di controllo esteso
Turbina a vapore
1920 1930 1940
Propulsione elettrica
1990 2000
19601970
Turbina a gas
1950
Convertitore di frequenza
1980
© ABB Group June 4, 2012 | Slide 8
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
PLUTOSafety PLC
ABB in Safety MarketLarge portfolio
Safety 2600TPressure Transmitter
System 800xA High Integrity
DTM
EDP300Position Master
© ABB Group June 4, 2012 | Slide 9
Safety 2600T Measurements
Pressure
Diff. Pressure
Level
Interface level
Volume
Flow
Density
ABB in Safety MarketInstrumentation
PRESSURE DETECTIONELEMENT 2 LINEARIZATION &
COMPENSATION
Standard architecture
Redundancy Diagnostic
OUTPUT2
VOTING
COMPARATOR
VERIFYSUPPLY
COMPARATOR
WATCHDOG
4 20 mA SAFE OUTPUT
CLOCK2
A / DVERIFYOUTPUT
FAILSAFE
ENABLE
4 20 mA
OUTPUT1
HART
4 20 mA
PRESSUREDETECTIONELEMENT 1
Temperature sensor
LINEARIZATION &COMPENSATION
VALIDATIOND / A
CLOCK1
© ABB Group June 4, 2012 | Slide 10
Machine SafetyPluto Safety PLC
“All-master system and the best of new and traditional solutions”
© ABB Group June 4, 2012 | Slide 11
Machine Safety9 new product families
Training & Advice
Practical application of standards and regulations, along with CE-Labelling.
Pluto Safety PLC
A unique All-Master safety PLC fordynamic and static safety circuits.
Vital safety system
Dynamic safety circuit for several sensors in accordance with the highest safety category.
Tina adapter units
Transformation of static signals to dynamicsafety signals.
Safety relays
The market’s most flexible safety relays for different protection purposes and categories.
Stopping time & machine diagnosis
Used to stop time measurement, annualmaintenance and for troubleshootingmachinery.
Light curtain/light beam/scanner
Complete range of light beams, light curtainsand scanners.
Sensors/Switches/Locks
Dynamic non-contact sensors, key switchesand solenoid switches.
Control devices
Ergonomic three-position control units,two-handed control units and foot pedals.
Emergency stop devices
Emergency stop devices for dynamic and static safety circuits.
Crush protectio/Safety mats
Sensitive edges, bumpers and safety.
Fencing systems/safeCAD/Roller doors
A stable and flexible fencing system easy to install.
© ABB Group June 4, 2012 | Slide 12
© ABB Group June 4, 2012 | Slide 14
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
© ABB Group June 4, 2012 | Slide 15
800xA High Integrity System Overview Separate
Workplace
Remote Clients
System Servers
Process Automation
EngineeringWorkplace
Direct communication link
Module Bus
Safety
WorkplaceEngineering
System Servers
Control Network
© ABB Group June 4, 2012 | Slide 16
800xA High Integrity System OverviewIntegrated
Workplace
Remote Clients
Process Automation
EngineeringWorkplace
Module Bus
Safety
WorkplaceEngineering
System Servers
Control Network
© ABB Group June 4, 2012 | Slide 17
800xA High Integrity System Overview Combined
Workplace
Remote Clients
Process Automation
EngineeringWorkplace
Module Bus
Safety
WorkplaceEngineering
System Servers
Control Network
Process Automation and Safety
Same engineering tools Same human systems interfaceSame Alarm Management and SOESame historian Same audit trailSame asset and device managementSame or shared instrumentationSeparate control applications for BPCS and SIS
Embedded environment reduces duality and associated lifecycle costs of maintaining separate systems (i.e. less spare parts, common training, etc.)
800xA High Integrity System OverviewSimplified operation and maintenance
© ABB Group June 4, 2012 | Slide 18
© ABB Group June 4, 2012 | Slide 19
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
© ABB Group June 4, 2012 | Slide 20
Certificates 800xA High Integrity – ABB Safety Certificates
TÜV Product Service, the foremost independent certification agency in the business, has certified all product components on the 800xA Safety offering
Product Safety Certificate
Development Department Safety
Certificate
Safety Manual
© ABB Group June 4, 2012 | Slide 21
The FSMS consists of the Safety Team and of some other support functions / processes.
Company processes are defined and described in the QM; Processes associated with safety related issues are:
Front End,
Project Management,
Hw / Sw ProductionDocumentation and Testing,
Commissioning,
Service,
Supply Chain Management,
Human Resources.
CertificatesFSMS Functions
© ABB Group June 4, 2012 | Slide 23
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
© ABB Group June 4, 2012 | Slide 24
AC800M High IntegritySingle Configuration
SM811 PM865 Single I/O AI8880, DI880 and DO880TB840
© ABB Group June 4, 2012 | Slide 25
AC800M High Integrity Redundant Controller Configuration
The 800xA High Integrity system can be configured in a redundant controller configuration
800xA High Integrity offers availability figures comparable to or better than typical TMR systems
Availability up to 99.9999%
Redundancy and switch-over to stand-by unit allow continuous operation without time restriction upon failure of one of the redundant modules
4 CPUs
© ABB Group June 4, 2012 | Slide 26
S800 High Integrity I/OI/O Modules
DI 880 - 16 Channels
AI880A - 8 Channels HART pass through functionality
DO880 - 16 Channels
Features
Single and Redundant configuration
Hot Insertion and Hot Swap in redundant configuration
G3 Coating
Embedded Diversity
© ABB Group June 4, 2012 | Slide 27
AC800M High Integrity Communication Interfaces
Communication through mentioned modules certified “interference free”
I.e. can be used in a safety system, but not for a safety critical function
All certified interference free modules listed in the ABB Safety Manual
© ABB Group June 4, 2012 | Slide 28
AC800M High Integrity Peer To Peer Communication
Workplace
Remote Clients
EngineeringWorkplace
Module Bus
Safety
WorkplaceEngineering
System Servers
Control Network
Module Bus
Safety
MMSReadHI
Control Modules
Logic_B
Program
MMSDefHI
Control Modules
Logic_B
Program
Data type check added in both
Any simple data type can be communicated
AC800M High Integrity“Stand Alone” safety offering
Safety Logic SolverTUV Certified (SIL 3)ReliabilityHigh AvailabilityFault TolerantModular I/O
Configuration softwareCertified Configuration EnvironmentEasy to Use
Interface to existing BPCS or HMIOpen Protocol (i.e. Modbus)Easy to UseBidirectional (READ/WRITE)
Bypass and maintenance override facilities
© ABB Group June 4, 2012 | Slide 29
© ABB Group June 4, 2012 | Slide 30
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
Integrated engineering environment
Streamlined deployment and operational performance
Graphical function design
Reusable solutions
Operator graphics
Change management
Integrated documentation
EngineeringCommon environment
© ABB Group June 4, 2012 | Slide 31
© ABB Group June 4, 2012 | Slide 32
Engineering Compiler Restrictions
The compiler warns and / or prevents the engineer from designing dangerous code
For example complex code structures, loops etc
The compiler checks that all restrictions and rules necessary to achieve the intended SIL of the application are adhered to
An error is reported when a rule is violated and the attempted download to the controller is blocked
© ABB Group June 4, 2012 | Slide 33
Engineering On-line changes
Online changes can be downloaded to the controller without interfering with the running process
FB/CM parameters (e.g. trip limit)
Hardware settings (e.g. ISP value)
Logic
Downloads are protected by the “Access enable” function
Re-authentication can be configured to ensure that the user is authorized
This is also recorded in the audit trail
© ABB Group June 4, 2012 | Slide 34
Engineering Certified Libraries
System
AlarmEventLib
BasicLib
FireGasLib
MMSCommLib
ProcessObjBasicLib
ProcessObjExtLib
SerialCommLib
SignalBasicLib
SignalLib
SignalSupportLib
SupervisionBasicLib
SupervisionLib
© ABB Group June 4, 2012 | Slide 35
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
800xA enables streamlined routine work processes and optimal reaction to upset conditions
Process Portal provides:
The ability to display information from multiple sources and transform it into relevant information for a diverse set of plant users.
Personalized workplaces for focused information access
Maintenance supervisors, process engineers, managers and plant operators etc.
User profile based upon security log-in
OperationPersonalized workplaces for safety
© ABB Group June 4, 2012 | Slide 36
© ABB Group June 4, 2012 | Slide 37
OperationExample Operator Display
Personalized Workplace for Safety Personnel
© ABB Group June 4, 2012 | Slide 38
Operation Operator Interaction – Confirm On-Line Write
Time out handling in Safe On-line Write dialog (90 seconds)
Provides operators with a visual feedback and requires them to confirm the operation before execution
© ABB Group June 4, 2012 | Slide 39
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
© ABB Group June 4, 2012 | Slide 40
MaintenancePartial Valve Stroke
SIL3 safety valve controller
Emergency shutdown (ESD)
Emergency venting (ESV)
Enable integrated PST functionality
Launching a PST
Manual (DTM)
Local user interface (LUI)
Local control panel (LCP)
Scheduler (DTM)
DTM
Search engine for System 800xA (Aspect Object database)
Reports can easily be exported to Excel(two mouse clicks)
Examples of searches include:
Forced IO signals
Inhibited Function Blocks
Valves in Manual
Transmitters over a limit
Loaded as a system extension
Snapshot Reports aspects
Snapshot Report Template
Snapshot Report Viewer
© ABB Group June 4, 2012 | Slide 41
MaintenanceSnapshot Reports
© ABB Group June 4, 2012 | Slide 42
Contents
ABB in Safety Market
800xA High Integrity System Overview
Certificates
AC800M High Integrity
Engineering
Operation
Maintenance
Security
Users can be assigned with different permissions according to their responsabilities
Restriction of access to the SIS (operation and engineering)
High flexibility
SecurityRoles & Responsabilities
Pro
cess
O
pera
tor S
afet
y O
pera
tor P
roce
ss
Eng
inee
r Saf
ety
Eng
inee
r
Operate BPCS X X
Operate SIS X
Engineer BPCS X X
Engineer SIS X
© ABB Group June 4, 2012 | Slide 43
© ABB Group June 4, 2012 | Slide 44
SecurityMulti-authentication
OPC properties can be configured to require an explicit authentication operation before the operation can be performed
Re-authentication
Double authentication
Intended for process critical operations
The information is stored in the Audit Trail (including reason and comment)
If the authentications fails three times in a row the dialog box is terminated and a system alarm is reported to the administrator
© ABB Group June 4, 2012 | Slide 45
SecurityAudit Trail
The Security and Access Control System enable audit of all operator and engineering actions
Filtering of the audit event categories
Possible to disabled during commissioning (system administrator)
Audit actions examples
Alarm acknowledged
Configuration changed
Signal forced
Download
Reserved/Released