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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
3Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
4Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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”.
5Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
6Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
7Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, Cover
A revolution in Safety Instrumented System
Expanding the Safety Spectrum
ProSafe-RS offers something more beyond conventional ESD (emergency shutdown) system.
8Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
9Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
10Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
11Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
12Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, One process : one network, one window
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.
13Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
14Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Data exchange between Safety controllers
V net
CS 3000 HIS
CS 3000 FCSSafety Controller
Safetycommunication
-> Safety Communication is available on Vnet.(Yokogawa original safety protocol, TUV certified)
No affect to safety comm.
Product BU, one network
15Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Data access to Safety Controller
V net
CS 3000 HIS
CS 3000 FCSSafety Controller
Safety Data to FCS
-> No interface module is required.
Product BU, one network
Tag access
16Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
V net
CS 3000 FCSCPU node
Product BU, one network
CS 3000 HIS is V net
Timemaster
Time Synchronization by Standard V net function
GPS as an option (IRIG interface on SCS)
17Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Merits of Common ArchitectureStandard design of cabinet layoutStandard way of Hardware replacement
FIO
18Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, One process : one network, one window
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.
19Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
20Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
System status
Product BU, One window
SCS FCS
21Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Process alarm
ProSafe-RS
All of CS3000 and ProSafe-RS
Product BU, One window
22Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
System Alarm
ProSafe-RS
All of CS3000 and ProSafe-RS
Product BU, One window
23Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
1ms resolution
・ Time & Date・ Event name ・ Comment・ Data
Product BU, One window
Yellow shows the trip event
24Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
25Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, Simple solutions are always best
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.
26Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
27Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, Simple solutions are always best
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.
28Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
29Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
××
×
30Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
31Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
*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
Product BU, Highly scalable architecture
32Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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, Highly scalable architecture
33Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
34Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, A breakthrough in size reduction
Upper blue area mentions about engineering with IEC 61131-3.
35Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Engineering tools IEC 61131-3 Function Block Diagram & Ladder
DiagramSystem & I/O configurationTest (Simulator on PC / Real target)Self documentationVersion Control
36Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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)
37Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, VigilantPlant
38Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
39Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, Solutions for the safety environment
These area mentions about our history, current products and support for them.
40Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Product BU, Solutions for the safety environment
This network configuration is available. Control domain and safety domain integrated with BCV are also available.
43Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
44Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
45Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
46Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Integration BU, Key Features of Integrated Solutions
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.
47Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Integration BU, Key Features of Integrated Solutions
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.
48Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
49Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Integration BU, Features of ProSafe-RS
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.
50Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Integration BU, Features of ProSafe-RS
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.
51Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
52Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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.
54Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
VigilantPlant BU, Cover
Integrated Plant Safety Managementfor Alert Manufactures
55Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
Integrated Plant Safety Management
Safe plants call for more than emergency shutdown. Let’s look at the big picture.
56Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
57Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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
58Industrial Safety Systems Dept. Copyright © Yokogawa Electric Corporation
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