Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 1 Product Details March...

Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation

1

Product Details March 1, 2005 MK, Industrial Safety Systems Dept.

2Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation

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 　


ProSafe-RS product color

The color gives active image of “safety” and expresses our willingness to provide the

best 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.


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 architecture

ProSafe-RS aims not only the integration of SIS to DCS, but also our consistent business frame “from sales to service & support”.


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


Available safety-related catalogues

Product Bulletin (Safety Instrumented System ProSafe-RS) Bulletin No: BU32S01B10-01E

Integration Bulletin (Integrated Production Control System CENTUM CS 3000 R3 Safety Solution) Bulletin No: BU33Q01A11-01E

VigilantPlant Bulletin vol.2 Bulletin No: 00A01A21-22E


Product BU, Cover

A revolution in Safety Instrumented System

Expanding the Safety Spectrum

ProSafe-RS offers something more beyond conventional ESD (emergency shutdown) system.


Product BU, traditional DCS-SIS

ProSafe-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.


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


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.


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.



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.


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


Data exchange between Safety controllers

V net

CS 3000 HIS


Safetycommunication

-> Safety Communication is available on Vnet.(Yokogawa original safety protocol, TUV certified)

No affect to safety comm.



Data access to Safety Controller

V net

CS 3000 HIS


Safety Data to FCS

-> No interface module is required.


Tag access


V net

CS 3000 FCSCPU node


CS 3000 HIS is V net

Timemaster

Time Synchronization by Standard V net function

GPS as an option (IRIG interface on SCS)


Merits of Common ArchitectureStandard design of cabinet layoutStandard way of Hardware replacement

FIO



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 solution

reduces the time and cost required to total process safety.


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


System status


SCS FCS


Process alarm

ProSafe-RS

All of CS3000 and ProSafe-RS



System Alarm

ProSafe-RS

All of CS3000 and ProSafe-RS



1ms resolution

・ Time & Date・ Event name ・ Comment・ Data


Yellow shows the trip event


Product BU, Simple solutions are always best

The complex discussion of SIS mechanisms are understood only by specialists.

ProSafe-RS brings clarity by its intrinsically-simple design providing perfect SIL3-rated safety to deal with the most of safety requirements.SIS based on the same design philosophy with DCS can dramatically reduce the time and cost required to select and implement SIS solutions.



A single, simple, SIL3 solution

Yokogawa’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.


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



Plug-in availability

Dual 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.


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


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

××

×


Product BU, Highly scalable architecture

ProSafe-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.


*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



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, 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.


Product BU, A breakthrough in size reduction

Upper blue area mentions about engineering with IEC 61131-3.


Engineering tools IEC 61131-3 　 Function Block Diagram & Ladder

DiagramSystem & I/O configurationTest (Simulator on PC / Real target)Self documentationVersion Control


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)


Product BU, VigilantPlant


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.



These area mentions about our history, current products and support for them.



This network configuration is available. Control domain and safety domain integrated with BCV are also available.


Product BU, END


Integration BU, Cover

CENTUM CS 3000 R3Safety SolutionProSafe-RS

This BU emphasizes, “ProSafe-RS is a family of CENTUM CS3000”.

This BU is made also for system sales and CENTUM customers who are not so familiar with safety system (or ProSafe).

Many of the ProSafe-RS product bulletin contents are repeated in this bulletin.


Integration BU, Introduction

YOKOGAWA’s new groundbreaking safety instrumented system, ProSafe-RS, can be plugged onto the same network of CENTUM CS 3000 R3.

No gateway or interface hardware is required for data exchange between DCS and SIS functions.

This innovative seamless architecture realizes the true integration of CENTUM and ProSafe while reducing the time and cost to implement process safety.


Integration BU, Key Features of Integrated Solutions

1. Common Human Machine Interface (HMI)

Operators can access to safety data by using the same HMI used by CENTUM CS 3000 R3.

The unified architecture eliminates the conventional needs to set up separate monitoring environments for DCS and SIS.

With the accustomed maneuvers, operators can predict critical conditions in much simpler ways.



2. Shared Maintenance Procedures

Common standards for DCS and SIS architecture contribute to lower the maintenance overhead.

Since the product colors of CENTUM CS 3000 R3 and ProSafe-RS are different, operators can easily distinguish between control and safety, which contributes to enhanced plant safety.



3. Unified Alarm

CENTUM CS 3000 R3 process alarm and ProSafe-RS safety alarm are merged and displayed in a single window on HIS.

The unified monitoring and event data allows operators to be fully aware of critical conditions and to take quick action in case of emergency.


Integration BU, Features of ProSafe-RS

1. Meeting Safety Standards

The 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.



2. High Degree of System Availability

While 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.



3. Highly Scaleable Architecture

ProSafe-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.


Integration BU, Example windows

Control 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.


Integration BU, Integration / separation

The control functions and safety functions are separated by controllers.

Control information and safety information are integrated and displayed on HMI.


Integration BU, END


VigilantPlant BU, Cover

Integrated Plant Safety Managementfor Alert Manufactures


Integrated Plant Safety Management

Safe plants call for more than emergency shutdown. Let’s look at the big picture.


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


KNOW IN ADVANCE

Protect Reactively, Analyze Retrospectively...

...or Predict, Avoid, and Minimize Emergency

Reactive 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


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


VigilantPlant BU, END


Thank you for your attention.

Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation 1 Product Details March...

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