Martin Högberg, RMU North Europe, September 2009
Control Systems College 2009
Selling Safety in All Applications
Content

30 Years of experience with Safety Systems

Technical information


Integrated Safety

SIL3 certification and standards

Embedded diversity

Quad CPU configuration

High availability

Country certification and certification process
Competition information

© ABB Control Systems
March 24, 2016 | Slide 2
HIMA, Invensys, Siemens, Yokogawa, Honeywell,

Sales arguments with some additional specification

Customer and reference list of ABB customers

FAQ
30 Years in Safety
Unmatched experience in harsh
environments
30 Years Of Experience With Safety Systems
Pioneering Installations & Long-Term Support


“ For an ocean of safety
experience you can
trust...”
© ABB Control Systems
March 24, 2016 | Slide 4
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
30 Years Of Experience With Safety Systems
Technology Driver And Leader
800xA High Integrity:

ABB has introduced and marketed systems based on all
major accepted architectures including

Simplex – 800xA High Integrity (SIL2 w/SM810)

DMR – Safeguard, 800xA HI (SIL3 w/SM811)

TMR - Plantguard

Quad - 800xA HI (SIL3, Redundant w/SM811)
Safeguard:

Developed for harsh and demanding offshore conditions

800xA High Integrity employs Embedded Diversity (unique
in the market place)

ABB not married to any specific architecture, only to safety
integrity
Plantguard:
© ABB Control Systems
March 24, 2016 | Slide 5
30 Years Of Experience With Safety Systems
Safety systems installations across the globe
 17
SIL3 800xA HI
projects in less
than 1 year!
Legend
 Safety
installation
 No safety
installations
© ABB Control Systems
March 24, 2016 | Slide 6
 170
SIL2 800xA
HI projects since
2005.
Integrated Safety
Flexible architecture for every need
System Overview
Separate Systems
Engineering
Engineering
Workplace
Workplace
System Servers
System Servers
Process Automation
Safety
Direct communication link
Variable Speed Drives
MCC
S800 I/O
S900 I/O
(Ex)
System Overview
Integrated BPCS and SIS
Remote Clients
Maintenance
Workplaces
Operator
Engineering
System Servers
Control Network
Process Automation
Variable Speed Drives
MCC
S800 I/O
S900 I/O
(Ex)
Safety
SIS and BPCS – same but separated
Remote Clients








Variable Speed Drives
MCC
Same engineering tools
Workplaces
Same human systems interface
Maintenance
Operator
Engineering
Same Alarm Management and SOE
System Servers
Same
historian
Same audit trail
Control Network
Same asset and device management
Process Automation
Same
or shared instrumentation
Separate control applications for BPCS and SIS
S800 I/O
S900 I/O
(Ex)
Safety
… and combine them
Remote Clients
Maintenance
Workplaces
Operator
Engineering
System Servers
Control Network
Process
Automation
and Safety
Process Automation
Variable Speed Drives
MCC
S800 I/O
S900 I/O
(Ex)
Variable Speed Drives
MCC
S800 I/O
S900 I/O
(Ex)
Safety
SIL3
Reliability you can trust
Certificates
ABB Safety Certificates
Product Safety
Certificate
Development
Department Safety
Certificate
Safety Manual
TÜV Product Service, the foremost independent certification
agency in the business, has certified all product
components on the 800xA Safety offering
Technical information
800xA High Integrity – Meets Industry Standards
© ABB Control Systems
March 24, 2016 | Slide 18

Safety Controller – SIL 1-3 / AK 1-6 / CAT
1-4 certified

S800 Safety I/O (AI, DI, DO) – SIL 1-3 /
AK 1-6 / CAT 1-4 certified

I/O Communication – SIL 1-3 / AK 1-6 /
CAT 1-4 certified

Standard I/O and communication modules
– certified interference-free* (*Listed in
safety manual)

Please refer to Safety manual for further
information
800xA High Integrity Controller and I/O topology
Single Configuration – SIL3
SM811
© ABB Control Systems
March 24, 2016 | Slide 19
PM865
TB840
Single I/O AI880, DI880 and DO880
800xA High Integrity Controller and I/O topology
Redundant/Quad Configuration
TB 840
SM811 BC810 PM865
Redundant I/O
Optical ModuleBus
CEX-bus
RCU Link
© ABB Control Systems
March 24, 2016 | Slide 20

Redundancy and switch-over to standby unit allow continuous operation
without time restriction upon failure of
one of the redundant modules

Reliability and availability matching and
surpassing TMR
800xA High Integrity Controller and I/O topology
Quad Controller Configuration (QMR)

The SIL3 800xA High Integrity system
enables Quad controller configuration

4 CPUs
© ABB Control Systems
March 24, 2016 | Slide 21
Redundant PM865 and SM811
provides 4 logic solvers creating
Quad configuration

Quad configuration in the 800xA High
Integrity system enables availability
figures comparable to or better than
typical TMR systems

With Quad availability up to 99.9999%
possible
800xA High Integrity Controller and I/O topology
SIL 3 certified I/O Modules

DI880



Features

Single and redundant
configuration

Hot Insertion and Hot Swap in
redundant configuration

Ex certified – Zone 2, Class 1
Division 2 according to US
standard

Embedded Diversity
AI880A

8 Channels

HART pass through
functionality
DO880

© ABB Control Systems
March 24, 2016 | Slide 22
16 Channels

16 Channels
Embedded Diversity
Reducing the risks of common cause
failure
800xA High Integrity
Diverse Architecture, Diverse Implementation
CB
AC800M HI
SIL3
PM
SIL3
SM

The SIL 3 800xA High Integrity controller
(1oo2D) 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
Safety I/O SIL3
HFT
SFF (%)
< 60
60 - 90
90 - 99
> 99
0
SIL 1
SIL 2
SIL 3
1oo1D
1
SIL 1
SIL 2
SIL 3
SIL 4
1oo2D
IEC61508-2 Table 3
800xA High Integrity – SIL3 Certified
Embedded Diversity – Unique In The Marketplace


Software diversity in logic solver – PM865 & SM811

Different operating systems

Different base software layers

Different un-packing procedures
Hardware diversity in S800 High Integrity I/O modules

Each card has two diverse execution paths based on
different hardware technology, MCU and FPGA
respectively
0
1
0
1
2
3
4
0
a1 Vcc1 Vcc2 b1
a2
0
a1
0
5
1
6
2
a1
b2
a2
MPU READ
7 CODE
3
a3
b3
a3
8
4
a4 GND GND b4
a4
0
Vcc1
Vcc1
RAM
GND
0
b1
0
b1
b2
b3
b4
5
2
6
7
3
8
4
0
0
a2
a3
5
&
b2
FPGA
a4
b3
b4
GND
0
6
7
8
800xA High Integrity – SIL3 Certified
Compliant At The Top Of The Range
IEC61508 Requirements
Safety Integrity
Level
Probability of
Failure on
Demand (PFD)
SIL4
Risk Reduction
Factor
Typical
Application
>=10-5 to < 10-4
100000 to 10000
Train, Nuclear
SIL3
>=10-4 to < 10-3
10000 to 1000
Emergency
Shutdown (ESD)
SIL2
>=10-3 to < 10-2
1000 to 100
Fire & Gas,
Process
Shutdown
SIL1
>=10-2 to < 10-1
100 to 10
Others
(Low Demand of
Operation)
SFF
Hardware fault tolerance (see Note)
0
1
2
< 60 %
Not allowed
SIL 1
SIL 2
60 % - < 90 %
SIL 1
SIL 2
SIL 3
90 % - < 99 %
SIL 2
SIL 3
SIL 4
≥ 99 %
SIL 3
SIL 4
SIL 4
Note: HFT of N means that N+1 faults could cause a loss of the safety
function

800xA High Integrity
Performance
800xA High Integrity qualifies in the
top range of the requirement bands
Quad capability
Offering the highest levels of fault
tolerance
Redundant Equals Quad
What is a Quad or QMR Configuration?

The industry recognizes the terms Quad and QMR as
marketing terms - these architectures are not a true 2oo4.

It has a hardware fault tolerance of 1.

In real terms, these architectures are essentially dual
arrangements in terms of inputs and outputs, and the
“Quad” term tends to refer to having four processors (two
per leg).” “2oo4D” Quad System
High availability
Never stop producing
Availability Prediction Tool

Easy to use Excel tool for calculating system
availability
800xA High Integrity
On-line upgrade of AC 800M HI

Online upgrade of firmware of
AC 800M HI CPU module supported from SV 5.0 SP1
and onwards
Note: Online upgrade of firmware requires redundant CPUs

Workstation & Server level must be same or higher
version than Controllers

Normally upgraded first

Can be upgraded independently of the controller
layer

Enables adding controllers without upgrading all
controllers in the installation
General workflow
1.
Decouple redundant CPUs
2.
Upgrade the Backup CPU
3.
Bring the Backup CPU up as
Primary
4.
Upgrade the new Backup CPU
5.
Enable redundant CPU mode
Sales and references
Technical information
Competency requirements on the purchaser
Requirements
© ABB Control Systems
March 24, 2016 | Slide 38

Requirements on individuals, i.e. safety proposal-, leadand project engineers

ABB require the following training scheme/competence
from the purchaser:

General 800xA training (e.g. T315, T314)

Specific safety system training for 800xA HI systems
T309

General Functional Safety training, can for instance be
acquired either through ABB University (T140) or
external training providers such as Exida, Risknowlogy
or TUV (Note: Only sufficient competence required, not
certification)

Safety project experience, i.e. experience acquired
though participation in safety projects
Requirements for Sale and Delivery of
800xA High Integrity Products
Safety Channel Partner Program
© ABB Control Systems
March 24, 2016 | Slide 39

Minimize risk to humans, assets and the environment by
ensuring correct deliveries of safety systems based on
800xA High Integrity products

Ensure that ABB acts as a responsible safety product
supplier

Minimize business and other risk to ABB

Safety Channel Partner Program, please contact your
respective Regional Market Unit through the corresponding
contact person:

Northern Europe (in Sweden) Martin Hogberg

Central Europe, Middle East and Africa (in Germany) Peter
Rother

Americas (in United States) Luis Duran

Asia Pacific (in Singapore) Darran Lim
Competition information
World wide volume and competition split
others
18%
Invensys
23%
Rockwell
2%
Yokogawa
6%
Siemens
6%
Honeywell
15%
Hima
8%
ICS Triplex
11%
ARC 2005= $923.1 M
© ABB Control Systems
March 24, 2016 | Slide 40
ABB
11%
Competition information
World wide target markets split
Power, Nuclear
3%
Other
5%
Power, Fossil
8%
Pharma
1%
Oil&Gas
40%
Chemical
20%
ARC 2005= $923,1 Mio
© ABB Control Systems
March 24, 2016 | Slide 41
Refining
23%
Customer and reference list of ABB customers
First Integrated System
Control system evolution of integrated
process control and safety systems
solution optimize safety and control
 When
Gullfaks A, North Sea
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 three (3)
generations of systems.
© ABB Control Systems
March 24, 2016 | Slide 42
Customer and reference list of ABB customers
Worlds Largest Platform
The largest platform on the planet

Troll A is the largest platform ever built.
It produces about 75 million sccm 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.

The new safety system went online in
June 2009 and constitutes the first SIL3
capable 800xA High Integrity installation
in the world.
Troll A, North Sea
© ABB Control Systems
March 24, 2016 | Slide 43
Customer and reference list of ABB customers
Safety Consulting
SIL Determination in gas separation
plant –Compañía Mega (Argentina)

Utilizing ABB’s Argentinean Safety
Execution Center as coordinator and
consultant, implemented a plan for the
functional safety of their separator plant,
fractionating plant and 600km of their
pipeline.

The project began with SIL
determination of more than 500 safety
instrumented functions through
utilization of the Calibrated Risk Graph
method, in accordance with the
IEC61511 standard.
Compañía Mega, Argentina
© ABB Control Systems
March 24, 2016 | Slide 44
Dong Naturgas
Nybro Gas Storage / Terminal Facility Upgrade

Emergency Shutdown
System

Expected Operation
October 2009

6 Redundant Controllers
Recent Safety Enhancements
Autronica Autrosafe Suite

SIL2 certified interface between the Autronica Autrosafe
Fire & Gas Central and 800xA High Integrity

The interface product is not part of the BU PIP 800xA High
Integrity system, but a separate licensed product from BU
OGP Norway

For more technical information and pricelist, please contact
ABB OGP in Norway

Contact: Roy Vidar Andreassen

E-mail: roy-vidar.andreassen@no.abb.com
System Configuration Example
SIL2 Certified
Serial
Communication
Link
Living Quarters
Control
Room
Local Fire
Alarm System
HVAC
Addressable Fire
detection loop
Sprinkler
Gas
Processing
Summary
Sales arguments with some additional specification
SIL3 800xA HI System
© ABB Control Systems
March 24, 2016 | Slide 54

Seamless integration on All levels
reduces complexity

Common HMI simplifies operational
excellence

Single engineering environment
reduces engineering

Engineering functions

Operation functions

Embedded firewalls

Asset Management functions

Common system reduces training

Single supplier provides single
support organization
Sales arguments with some additional specification
SIL3 800xA HI System advantages
© ABB Control Systems
March 24, 2016 | Slide 55

Embedded safety bypass management
during different states of control

The control application can read
parameters within the safety application
in real time to optimize control of safety
distances

The SIF (safety instrumented function)
instruments can also be used in the
BPCS application

Highly engineered Certified Application
Libraries

ESD

F&G
What to remember
© ABB Control Systems
March 24, 2016 | Slide 56

ABB provides 30 years safety solutions

The SIL 3 800xA HI Safety system can be engineered up
to a Quad configuration with availability up to 99.9999%

True seamless integration.