IndustrialIT System 800xASafety

Overview

Features and Benefits

■ Embedded High Integrity Control andSafety: Control and safety delivered in asingle environment eliminates interfacing,cost and complexity, and widens thefunctional scope.

■ Improved Reliability, Availability, andScalability of Overall PlantOperations: AC 800M HI controllercombines safety critical loops with controlapplications to facilitate maximum utiliza-tion of process equipment within definedsafety boundaries during changingproduction modes.

■ Comprehensive Safety FunctionalityMeets Industry Standards: Providescomplete safety instrumentation, comply-ing with IEC 61508 and including SILrated controllers, I/O and instrumentation.

■ Total Lifecycle Management: SIL-compliant function libraries streamline theengineering workflow, from concept,design and implementation, to operationand maintenance.

■ Reduces Time to Decision and Action:Intuitive operator interface and advancedreporting features monitor production,identify developing situations, and takeappropriate actions, all while minimizingrisks.

■ Optimizes Plant Availability andPerformance: Real-time plant assetmanagement features increase plant avail-ability and safety integrity through earlydetection of performance problems andefficient remediation processes.

■ Safety Services: Services span the com-plete asset and safety lifecycle, providingsafety consultancy, SIL assessment, soft-ware and hardware technologies support,and maintenance support.

Reducing Risk through High IntegrityAutomation

Industrial IT Extended Automation System 800xA improvesprocess availability while reducing the risk to overall plantoperation by providing a common environment for produc-tion control, safety supervision, and production monitoring.Within this environment, System 800xA offers a completeSafety Instrumented System (SIS) solution, complying withthe IEC 61508 and IEC 61511 standards and covering, notonly the logic solver, but also entire safety loops, consistingof field instruments, central controllers and field actuators.

SIS realization is achieved by utilizing dedicated controllersor via SIL designated applications within the same controlleras process control. By utilizing common hardware andsoftware, System 800xA can reduce costs significantly. In thisway, the objectives of both systems are achieved: maximumplant availability and minimum risk.

With safety applications such as emergency shutdown systems,fire and gas systems, and burner management, 800xA Safetydelivers safe reliable operation of any industrial process.

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Introduction

In today’s fast-paced global economy, competitive advantages result when acompany can tap into its assets’ unused productivity safely and effectively tomeet changing demand. Continuous pressures to reduce costs are balanced bythe company’s social responsibility to protect their people, property, environ-ment, and the surrounding community from harm. With the increasing accept-ance of “smart” equipment, the process industries are experiencing a revolution;demanding closer integration of safety and control systems, safety functions atvarying states, and flexibility, scalability, and reusability of safety components. Inaddition, the process industries require safety system certification and protectionof their installed system investments.

ABB has more than 25 years of experience in designing, implementing, andmaintaining fault-tolerant, programmable, safety systems for oil and gas, petro-chemicals, fine chemicals, and power generation applications. Through System800xA’s common operations, engineering, and information environment for BasicProcess Control Systems (BPCS) and Safety Instrumented Systems (SIS), ABBprovides safety solutions that are easily scalable from a few loops to completesafety systems.

The 800xA Safety offering, as described in this document, includes the following:

■ A unified, high integrity system architecture

■ A complete SIL compliant SIS solution

■ Total lifecycle management engineering environment

■ Personalized workplaces for safety personnel

■ Information management for safety

■ Safety asset optimization

■ Safety services

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Figure 1. System 800xA’s high integrityarchitecture provides a unified environment forembedded safety and process control.

High Integrity System Architecture

Today, companies require tighter integration among safety and control applica-tions. The industry is calling for SIS solutions that are cost effective throughintegration with control systems, less frequent proof-testing, and scalablearchitectures. The 800xA system satisfies these objectives by providing a func-tional building block approach for system design to meet every system applica-tion need. Based on ABB’s patented Industrial IT Aspect Object technology and acommon set of hardware, System 800xA seamlessly integrates traditionally iso-lated plant devices and systems. This unique unified, high integrity architecturereduces duality and associated lifecycle costs of maintaining separate BPCS andSIS systems. Project engineering, training, operations, maintenance and spareparts are optimized through the use of the common architecture.

The 800xA system architecture offers the flexibility of hosting both safety andprocess critical control applications in the same controller (see Figure 1). The AC800M HI controller is supported by common engineering tools, human systeminterface, historian, audit trail, asset and device management applications, andinstruments; thereby improving the overall integrity and reliability of BPCS andSIS operations. Such an environment offers safe, instant, interaction betweenapplications; leading to a host of benefits, from easier handling, through bettertechnical solutions, to lower costs.

Embedded Safetyand Control

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Overall, tight integration between BPCS and SIS applications offers the followingadvantages:

■ Embedded safety bypass management during different states of control(example: start up, product changes, sequence stepping, maintenance work).

■ Safety parameters can be easily adapted automatically to process, phase, orproduct changes.

■ The control application can read parameters within the safety application inreal time to optimize control of safety distances (example: dynamic adaptationto one or different safety boundaries).

■ Faster interaction between control and safety applications.■ The same instruments can be used in both safety and basic control application.■ Dual instruments facilitate comparison of signals for higher safety.

When safety and process applications are executed within the same controller,they can freely exchange signals and data without the need for external, com-plexity adding, interface hardware, software, and mirroring of data. However,safety integrity is secured by certified embedded firewalls.

System 800xA’s extensive diagnostics and firewall mechanisms eliminate common-cause failures of control and safety circuits.

System security. At the highest level, 800xA safety system integrity is protectedthrough inherent system security features, such as user log-overs, data accesscontrols, and advanced security features. Operator actions in the system can beassigned different permissions. This assignment defines the permissions a userneeds to perform his/ her duties. Examples of permissions are: Read, Configure,

and Operate. Each attribute of a controlobject can be assigned a different per-mission, so that access rights can bedifferentiated down to the level ofindividual commands directed at indi-vidual control object. Time-stamped audittrails document all changes made to thesystem in terms of user and nature.

Embedded firewall mechanism (Ac-cess Management). Access Control toapplications, Confirm Operation andForce Control are all firewall mechanisms(Access Management) embedded withinthe safety controller (see Figure 2).

Access Control to SIL applications in-cludes functionality for configuration,operations and maintenance. Whendesigning a SIL application, each safetyobject is given an applicable access level;Read Only, Confirm or Confirm andAccess Enable. In Operations, these SILaccess levels are automatically enabled.However for the highest access level, aphysical input must be enabled to secureauthorized access. When Access Enable isactive, permission is given to makeonline changes in the SIL application.

Figure 2. Embedded firewalls and confirmation procedures protectthe SIL application from inadvertent/accidental control actions.

System Security andEmbedded Firewalls

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R e a l o b j e c t s

S a f e t y W o r k p l a c e

S a f e t y A s p e c t sSafety requirements specification

& Safety analysis report

Reliability calculation

SIF Design & SIS configurationand programming

Compliance Manager

Requirements &compliance management

HAZOP / Risk idenfication indexIEC 61508 / Risk classification

Confirm Operation, together with Access Control, is the embedded firewall mecha-nism for safe access of object variables during operation and maintenance.

Force Control, Override Control, or Bypass Management functionality is necessaryto maintain availability of the process in many situations, for example duringautomatic startup or maintenance of SIS related field equipment.

The Force Control in the AC 800M HI follows the lifecycle of the SIS. During designof a SIL application, the safety engineer defines the maximum number of concur-rent forced inputs and outputs. During operations and maintenance, the AccessManagement SW keeps track of the active number of forced I/O points. Thisinformation is presented via the safety operator's personalized workplace. TheOperator may set and reset forces from the workplace. For an emergency reset ofall forces a firmware function including a dedicated physical input is available inthe Logic Solver. This both complies with regulatory requirements as well as re-duces time consuming application design, implementation and testing.

The framework for the 800xA high integrity system environment is built upon ABB’sAspect Object technology. Managing data within this singular virtual databaseenvironment, System 800xA makes all information required to install, operate, andmaintain the system available through a common portal. This makes it possible toaccess data (aspects) directly from its source in the context of the asset (object)without needing to know where the data comes from, and without concern aboutdata integrity and concordance.

Figure 3. System 800xA makes data on all plant items available as aspects.Safety related aspects include: hazardous operation studies, safety requirementspecifications, configuration settings and application programs.

Functional SafetyManagement viaAspect ObjectsPlatform

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800xA’s system platform opens new perspectives in design and realization of safetyand control applications as well as in Functional Safety Management (FSM) andsafety related support functions (Figure 3). For example, safety aspects couldinclude hazardous operation studies, safety requirement specifications, safetyallocation specifications, SIL Assessments, installation and test support, mainte-nance, modifications and Change Management, Configuration Management, SILmonitoring and validation and verification (V & V).

800xA Safety systems are delivered and supported in accordance with the strict-est current standards. The high integrity system meets among others the IEC61508, IEC 61511, EN 954, NFPA 85 & NFPA 72 standards.

IEC61508 is an international standard titled "Functional Safety of electrical/electronic/ programmable electronic (E/E/PE) safety-related systems," and is ageneric standard providing guidance in the design of safety systems. Based onIEC 61508, IEC 61511 is process industry specific and entitled "Functional safety -Safety instrumented systems for the process industry sector." Other industries are

Meets IndustryStandards

Figure 4. ABB's Compliance Manageroffers a set of efficient tools formanagement of safety applications,from conception to maintenance.

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following suit. For example, the manufacturing industries will soon replace EN954 with IEC 62061.

In addition to guidelining product requirements, these standards specify proce-dures and routines for all activities required to manage safety throughout theentire lifecycle of the SIS system. This includes planning, design, implementation,documentation, training, operation, and maintenance. Due to its strict accordancewith the relevant standards, TÜV Product Service, the foremost independentcertification agency in the business, has certified all product components of the800xA Safety offering (Figure 5).

The 800xA system architecture is designed to ensure future enhancements insystem technologies will not compromise current investments. 800xA Safetyprovides users the ability to extend the scope of their installed control and safetysystems with high integrity safety functions. 800xA supported controllers aresummarized in Table 1.

Figure 5. 800xA Safety is certified to the IEC 61508 and IEC 61511 safety standards.

Table 1.

800xA supported controllers

AC 800M Series Safeguard 400 Series

Advant Master Series SATT & Sattline Series

Advant MOD 300 Series Symphony DCI Series

Freelance Series Symphony Harmony Series

Melody Series AC 870P Series

Extending InstalledSystem Capabilities

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Figure 6. Certified firewalls isolate SIL and non-SIL applica-tions from one another, enabling them to reside in the samecontroller and run concurrently.

Complete SIL Compliant SIS Solution

800xA Safety features a flexible and scalable SIL compliant design. 800xA highintegrity controllers and I/O (see Figure 6) are highly modular, offering manyinterconnection options and making them suitable for all safety and businesscritical process automation applications, from small to large. Through its modulardesign, AC 800M controllers and associated I/O options contribute to lower costs,higher engineering quality, and higher operating efficiency. SIS scalability resultsin a higher return on assets by providing the flexibility to choose the specificsafety functions required to meet actual plant needs.

Flexible andScalable Design

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■ AC 800M HI Controller. The AC 800M HI offers a TÜV certified controlenvironment for combining safety and business critical process control in onecontroller without sacrificing safety integrity. The AC 800M HI, in combinationwith a diverse co-processor, performs diagnostics and monitoring of applica-tion execution and I/O scanning. For embedded safety and control applica-tions, all functions/types in standard libraries are marked non-SIL or SIL toshow their usability. Embedded safety measures prevent inadvertant degrada-tion of safety applications.

SIL selection activates the relevant restrictions and limitations, such as onlySIL marked elements to be used in SIL applications. In SIL rated applications,it is possible to choose between three IEC 61131-3 languages, Function BlockDiagram, Structured Text, and Sequential Function Chart. For non-SIL applica-tions, all five IEC 61131-3 languages are available for use.

■ High Integrity I/O. System 800xA’s S800 I/O is a distributed, highlymodulized and flexible I/O system, providing easy installation of I/O modulesand process cabling. S800 I/O modules and its termination units can bemounted and combined in many different configurations to fit any spacerequirements or meet any application. A comprehensive assortment of I/Omodules and accessories are available for safety critical and non-critical use.Within the S800 I/O family, there are SIL3 compliant modules that can beused for safety critical applications. These I/O modules include those for 4 -20 mA analog inputs, 24 Vdc digital inputs and 24 Vdc digital outputs. Thedigital output module provides both Normally Energized (ESD) and NormallyDeenergized (F&G) outputs. Analog inputs support HART routing for easycalibration checking and diagnosis with configurable access, while the digitalinputs support local timetagging of signal changes for high accuracy se-quence-of-events logging.

■ High Integrity Instrumentation. ABB can provide a wide range of SIL-ratedsensors, valve positioners, and actuators.

Various solutions are available; from high integrity transmitters with fullredundancy (Hardware Fault Tolerance = 1) designed and certified by TÜVagainst IEC 61508 requirements to standard transmitters with enhancedinternal diagnostics to minimize the Probability of Failure on Demand. Thepositioner/actuator is available with a shutdown module allowing for overrid-ing of the control action in case of demand. All of these include third partycalculations/evaluation of safety performances / lambda to enable SIL loopcalculation / assessment.

The instruments internal diagnostics provide detailed information regardinginternal status. This information can be displayed by the system's asset moni-tor functions.

The instrument manuals define the proof test interval that, in the fully redun-dant version, can be extended up to 10 years.

The AC 800M HI safety controller is SIL compliant in a single controller architec-ture. Additionally, redundancy is available in all areas of the safety control and I/Osubsystem eliminating single points of failure and providing maximum availabil-ity. These include controllers, I/O, control networks, internal buses and powersupplies. When a fault occurs in a primary circuit, bumpless transfer to thebackup ensures uninterrupted operation (Figure 7).

Fault Tolerancefor MaximumAvailability

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Figure 7. System 800xA Safety includes redundant options in all critical areas for improved availability.

Two AC 800M HI’s can operate in parallel, one as the primary and the other asthe back-up. If the primary controller fails, the back-up takes over automatically.There is also a communication bus isolation and switchover scheme wherebyredundant fieldbus communications can be maintained unimpaired even if one ofthe two controllers fail.

According to user change management procedures, hardware modules, hardwaresettings, and applications may be changed on line, in real time, and under power,resulting in maximum control availability.

The AC 800M HI Controller offers enhanced availability. Advanced diagnosticsprovides higher integrity and better utilization of redundancy in business-criticalcontrol applications.

For complete AC 800M Control and I/O details, please refer to the AC 800MControl and I/O Overview.

Total Lifecycle Management

Providing a single, accurate, source of system information helps ensure dataconsistency and improves engineering performance throughout the lifetime of theplant automation system. Working within a common engineering environment,800xA Engineering supports a consistent information flow from design, throughinstallation and commissioning, to operation and maintenance (Figure 8). It laysthe foundation for continuous improvements in lifecycle and operation dimen-sions of information flow, resulting in engineering for maximum performance andreal increases in overall productivity.

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In general, System 800xA Engineering features include:

■ Total Asset Lifecycle Engineering. Opportunities to drive operationalperformance improvement begin early in the project lifecycle where key assetinformation is being created in core design systems. By using 800xA’s ProcessEngineering Tool Integration for INtools, not only can automation systemstructure, functionality, and graphics be created directly from the INtoolsdesign, but operational changes, such as ranges, units, and settings, can becontinually reflected back to INtools. Engineering savings of 40% and opera-tional savings of 20% are achievable from reduced as-built cycles and byautomatically maintaining design synchronization.

■ Graphical Function Design. Graphical function design enables engineers tobe engineers instead of programmers. Provides graphical design of the entirecontrol loop - from field devices to process logic. This enables easier engi-neering and maintenance of IEC 61131-3 applications.

■ Device Management. Device management for intelligent devices providesthe tools to engineer device integration from topology on down to the fieldelements, including device parameterization, application planning, commis-sioning and detailed diagnostics.

■ Reusable Solutions. Facilitates the incorporation of “best practice” standards.The common framework allows logically defined solutions to be quicklyreproduced and adapted to meet specific needs with minimum engineeringand re-validation. When modifications are made to existing standards, in-stances are automatically updated.

■ Operator Graphics. Interactive operator graphics can easily be customizedthrough the use of predefined elements and symbols.

Figure 8. Safety logic development within the 800xA Engineering environment.

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800xA’s object oriented engineering environment with SIL-compliant functionlibraries efficiently supports the entire safety lifecycle. The 800xA engineeringenvironment includes safeguards against non-SIL compliant configurations. Onceidentified as a safety application, the engineering system will automatically limituser configuration choices and will prevent download if SIL requirements are notmet.

A series of safety measures are implemented both for the downloading processand runtime environment. These measures form an important part of the firewallmechanism for Embedded Control and Safety. CRC protection on different levels,double code generation with comparison and compiler with revalidation are justa few examples of the AC 800M HI embedded firewall mechanisms.

Specifically, System 800xA provides the following additional measures for safetysystem engineering:

■ IEC61131-3 language usage■ Access control and override (force) control■ Application change report■ Cause and Effect design■ Application libraries and solutions

One of the many options for secure and efficient engineering is System 800xA'sCause & Effect Tool. This tool is used to design, verify and document cause-&-effect matrices used for shutdown and protection-related applications (Figure 9).A Cause & Effect matrix is a representation of the relationship between sets ofprocess inputs and the output actions they trigger. The tool supports the designof hierarchical safety shutdown levels and may be used to organize overallshutdown strategies. The Cause & Effect tool generates both the logic and theOperator Workplace's dynamic graphics.

SIL CompliantApplicationEnvironment

Cause and EffectDesign

Figure 9. System 800xA Safety's Cause and Effect Tool makes it easy to definevisually which safety (output) actions may be required and the input conditionsthat should trigger them.

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System 800xA includes a comprehensive library of standard reusable componentsthat include extended automation entities such as faceplates, graphic elements,trends, document links, and alarm and events. In addition, ABB provides a broadfamily of industry specific libraries that contain pre-configured Control Modules,Function Blocks, and graphic elements. These pre-tested proven libraries signifi-cantly reduce the time required to engineer, test, and maintain control applica-tions, while minimizing project risks (Figure 10).

Figure 10. 800xA’sFire & Gas library includes acomplete range of high-levelControl modules, AlarmManagement and operationaltemplates and strategies.

With more than 25 years of experience in designing, implementing, and main-taining safety systems, ABB provides a wide range of field proven applications,including:

■ Fire & Gas systems■ Emergency and Process shutdown (ESD and PSD)■ Interlock systems■ Burner Management and Boiler Protection (BMS)■ Critical Control■ High Pressure Protection Systems (HIPPS)■ Pipeline Protection systems (PPS)

For complete 800xA Engineering details, please refer to the System 800xAEngineering Overview.

SIL CompliantApplicationSolutions

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Figure 11. Personalized User Workplaces. System 800xA ProcessPortal presents plant information in the proper context at the right time,in the right form, and to the right people.

Personalized Workplaces for Safety Personnel

System 800xA’s Process Portal provides a single, consistent, and intuitive humansystem interface to access and interact with information included within theextended automation scope. In day-to-day operations, the safety level of a plantdepends mainly on the quality of the equipment, the execution of differentactivities, and the work flow process management. Analysis of major accidentsand catastrophes have shown that a series of unfortunate coincidental eventshave taken place prior to such incidents, and that adequate actions where nottaken in the first critical phase of fighting them. Therefore, knowledge, informa-tion availability, and overall plant awareness are the keys to the daily achieve-ment of plant safety.

Unique to Process Portal is its ability to gather information from multiple plantsources and transform it into relevant information for a diverse set of users. Forexample, it allows users, such as safety operators, maintenance technicians,engineers, or safety managers, to organize information and navigate throughoutthe system intuitively in the context of their job functions (Figure 11). The AspectObject navigation presents the entire production facility in a consistent, easy-to-view fashion. This allows a single window environment to include SIS fielddevices, I/O, and logic solvers, alarm and events, asset optimization functions,safety reports, etc. Therefore, by virtue of the system’s integration and its abilityto link to all information aspects of a process or safety object, root causes can bequickly identified and analyzed; allowing users to react to specific process andsafety related events in a safe, consistent, and timely fashion (Figure 12).

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Specifically, Process Portal can provide the following safety supervision func-tions:

■ Sequence of Events and Alarms (SOE). By time tagging events to millisec-ond accuracy, Event and Alarm SOE displays can identify the root causes oftrouble.

■ Object Signal Displays. Every field device connected to a safety controllerhas a corresponding predefined object display with real-time information anddialog with the device.

■ Access Management. During process startup, maintenance, and testing, it isnecessary to inhibit specific safety functions. With System 800xA, specificinputs may be inhibited and outputs bypassed through standardized operatordialog. Care has been taken in the design of access control, safety integrityand bypass status overview of System 800xA to combine ease of operationwith maximum safety integrity.

■ Diagnostics. Every element in the safety system and SIS loops are automati-cally included in the system status supervision function. Controller, I/O,communication, power supplies, field device, etc. status is monitored. SystemStatus and Asset Viewers provide detailed information about the health andlocation of the components.

■ Messaging. Remote personnel are notified of critical events via mobiletelephones, email accounts, and pagers by the system’s SMS (SimpleMessaging Service) and e-mail messaging service. Using GSM (Global Systemfor Mobile communications) mobile phone technology, 800xA allows remoteacknowledgement of notification and confirmation of receipt.

For complete 800xA Process Portal details, please refer to the System 800xAOperations Overview.

Figure 12. Examples ofoperator workplacedisplays: a process flowdiagram (above) and aFire and Gas alarmoverview (right).

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Information Management for Safety

Timely collection and distribution of reliable information to the plant’s decisionmakers is critical in today’s production environment. System 800xA InformationManagement provides the ability to collect and securely store business, process,and safety data from all plant sources. This data can be analyzed and transformedinto useful information, and presented to plant users to improve operationsefficiency, safety, and profitability.

System 800xA Information Management features include:

■ Intuitive Information Display. Desktop displays provide managers andother plant users concise, enterprise-wide system and process information ina familiar office presentation format without leaving their office workplace.

■ Automated System Actions. Versatile scheduling options provide automatictriggers for key system actions such as process or safety data collection,report generation, historical information archiving, and history data consolida-tion to provide a single plant-wide history repository, as well as back-upfunctions.

■ Flexible Report Generation and Distribution. A variety of reports aresupported included Microsoft® Excel and Crystal ReportTM providing veryfamiliar, easy-to-use formats. Standard report templates are included, whichoffer quick report set-up.

■ Secure Historical Data Storage and Access. Fault tolerant and distributeddata configurations provide dependable data and information availability.

Typical 800xA Compliance reports include:

■ Override Report. Gives an overview of all 800xA tags that are currently inforce, blocked, suppressed, in override etc.. It is also possible to review whena tag was e.g. blocked or suppressed and released historically.

■ Valve Verification Report. Summarizes valve functionality in the system.This report contains valve operation information, such as calculated valvetravel time and operation status, and a fault frequency report on valve andvalve groups. The operation status included are: excessive travel time, valvesnot operated during a given time, valves with fault, valves operating properly,valves with chatter on the limit switches and valves with quick operation(valves not reaching the limit switch due to a contradicting command). Thefault frequency portion of the report calculates the number of critical faultsthat occurred during a given period of time. The higher the fault frequency is,the more likely the valve will fail the next time of operation. The fault fre-quency is calculated for individual valves and pre-configured valve groups.The Valve verification can be configured to include all or some of the valvesin the system, and can include valves without limit switches, valves with onelimit switch (open or close) or valves with both limit switches available. SeeFigure 13.

■ Valve Leakage Test Report. Summarizes results from valve leakage testing.The Valve Leakage Test Report can be used on all valves, both critical andnon-critical. The report consists of logging pressure data for a valve after theoperator has created a pressure difference on the valve. The report presents

800xA ComplianceReports

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information in tabular and graphical views, so that any leakage can be identi-fied and necessary preventive actions can be performed. The valve leakagetest can be used on both manual and control valves. For valves withoutpressure measurements available in the process, the operator can enter thisinformation into the report manually.

■ Automatic Shutdown Report (ASR). First cause identification, shutdownlogic verification, and process equipment performance are all critical for safeand optimum production. ASR validates the success of a Process Shutdown(PSD) or Emergency Shutdown (ESD). The ASR report contains an overviewof all the shutdowns performed in the system, and gives the operator detailedinformation of all the causes and effects including status of the operationsperformed. The time taken for scrolling the event lists after a shutdown toverify the main cause and its effects is highly valuable. With the main shut-down cause verified, safety operators can restart the process as quickly aspossible. See Figure 14.

For complete 800xA Information Management details, please refer to theSystem 800xA Information Management Overview.

Figure 14. Automatic Shutdown Report

Figure 13. Valve Verification Report.

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Asset ConditionMonitoring

Safety IntegrityMonitoring /Proof Testing

OptimizedRemediationWork Processes

Asset Optimization

800xA Asset Optimization features significantly increase control and safety systemavailability while reducing maintenance costs through optimized remediationwork processes and early detection of asset performance problems.

Most failures of safety systems are not caused by logic solvers but by field de-vices. In conjunction with 800xA’s asset optimization features, the safety systemexploits the wealth of diagnostic information available in the instrumentation,logic solver, final elements, and electrical elements to assess and documentequipment conditions in real time. This information is collected, aggregated,analyzed, and compared with historical data to provide advanced notice ofdegrading performance and impending failure (Figure 15). These functionsenable personnel to schedule maintenance accordingly. Thereby, 800xA AssetOptimization real-time condition monitoring and reporting features can greatlyreduce the amount of costly corrective maintenance and time-consuming preven-tive maintenance required.

Safety Instrumented Systems are required to be proof tested on a regular basis toreveal hidden dangerous failures that cannot be detected and announced by theinherent diagnostics. The main concern resides with the field equipment and itsfunctional connection to the Logic Solver, equipment and connections thattypically have to be proof tested on a yearly basis.

The required proof test interval of safety-instrumented functions (SIF) is calcu-lated on the basis of reliability formulas in IEC61508.

With 800xA’s real-time plant asset management and information managementapplications, the need for off-line proof testing is dramatically reduced whileproduction uptime and safety integrity is correspondingly improved. Actualevents in daily operation are monitored, analyzed and used in the functionalverification and documentation of the integrity of individual safety instrumentedfunctions, thus extending the test interval by postponing proof testing.

Additionally, System 800xA’s integrated environment for device calibration andmaintenance management provides safety system users with a versatile plantlifecycle management and workflow optimization tool (figure 15). By providingcalibration and maintenance management within a single window interface, plantpersonnel can significantly reduce the maintenance cycle by interacting withequipment data and accurately access equipment conditions and status in realtime.

For complete 800xA Asset Optimization details, please refer to the System 800xAAsset Optimization Overview.

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Safety Services

ABB’s safety critical systems team provides a wide range of engineering servicesto a broad spectrum of users globally. The strengths of this team are founded ona proven knowledge of engineering issues from an end user / operator perspec-tive and on-going access to the capabilities of the total supply chain.

ABB Safety Services assists in the practical implementation of all phases of theIEC 61508 / 61511 safety lifecycle for both existing and new facilities by applyingproven techniques and working methods including:

■ Safety Integrity Level (SIL) assessments■ Software tools supporting the safety lifecycle■ Identification of safety critical elements / functions■ Safety lifecycle audits■ Functional safety assessments■ Independent validation & verification

- Hardware / software design - System integration

■ Support for strategies to implement IEC 61508 / 61511■ Support for in-house training and awareness programs.

For complete Safety Services details, please refer to the System 800xA SafetyServices Overview.

Figure 15. Asset Optimization reportingdisplays provide quick identification ofcritical plant performance conditions (left).Computerized Maintenance ManagementSystem (CMMS) resident information isreadily avaialble for viewing by right-clicking on the asset’s graphic element.Hyperlinks provide direct connection to thespecific work order located within theCMMS system (right).

Safety

3BSE038820R0001© Copyright 2005 ABB. All rights reserved.Specifications subject to change without notice. Pictures, schematics, and other graphics contained herein are published for illustration purposes only and donot represent product configurations or functionality. User documentation accompanying the product is the exclusive source for functionality descriptions.

Automation TechnologiesWickliffe, Ohio, USAPhone : +1 440 585 8500Fax : +1 440 585 8756www.abb.com/controlsystemsemail: industrialitsolutions@us.abb.com

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The IndustrialIT wordmark, Aspect Objects, and all above-mentioned names in the form XXXXXXIT are registered or pending trademarks of ABB.All rights to other trademarks reside with their respective owners.