Knowledge Center: Plant Safety
Safety With Foundation Fieldbus
Foundation fieldbus technology enables process end users to realize significant CAPEX and OPEX benefits by extending fieldbus benefits into plant safety systems. The Foundation for Safety Instrumented Functions (SIF) protocol has already been approved by TÜV to meet the requirements of IEC 61508 up to, and including, safety integrity level (SIL) 3.
In May 2008, the Fieldbus Foundation conducted a successful end user demonstration of its Foundation for SIF solution at the Shell Global Solutions technology center in Amsterdam, The Netherlands.
The purpose of this live technology demonstration, which attracted process automation end users and equipment suppliers from around the world, was to evaluate Foundation fieldbus-enabled safety valves with partial stroke testing (PST) capability, as well as various pressure, level, temperature and diagnostic devices. The demo also evaluated system integration capabilities with asset management and basic process control system (BPCS) platforms.
The Shell demonstration showed that even in the middle of a partial stroke test the emergency shutdown system could successfully take over and shut down the system during an abnormal situation. Two out of three (2oo3) voting was demonstrated using various fieldbus SIF devices. The system also reacted successfully to a loss of temperature probe, as well as a measurement validation alarm and a diagnostic alarm generated from a dry probe on a level device.
Audun Gjerde of Shell Global Solutions, who conducted the SIF demo at the Amsterdam event, commented, "By implementing Foundation for SIF, Shell expects enhanced diagnostics through a fully integrated asset management system. We also anticipate less testing of final elements thanks to smart testing and diagnostics, as well as online testing and partial stroke testing. This will result in early detection of dangerous device failures-and fewer spurious trips."
He continued, “The added SIF diagnostics will help engineers and maintenance personnel increase the integrity of the plant by ensuring maintenance is performed where and when it is needed. With smart online testing and diagnostics, we will be able to run for longer periods of time without shutting down the plant for testing purposes. We will also save on the cost of adding a second or third device in many cases.”
Successful Foundation fieldbus-based safety shutdown system demonstration at Shell Global Solutions technology center in Amsterdam, May 2008.
Pent-up demand According to an ARC end user survey for safety systems, there is a pent-up
demand for Foundation Fieldbus for process safety applications, which was reflected in the survey results. Over a third of the respondents indicated they were willing to use the present Foundation Technology for safety applications.
The difference between the demo of basic fieldbus functionality at Shell many years ago and the recent safety system demo is the high level of end user commitment that is already behind the technology. Most of the large integrated oil companies have already begun large-scale adoption of Foundation Fieldbus technology, and the availability of Foundation Fieldbus based safety systems has been widely anticipated. Shell has stated that they plan to use FF-SIF on their new projects starting in 2011.
But several hurdles must yet be passed before FF-SIF products are available on the market. Aside from product development and approval, future developments from the Fieldbus Foundation and member companies include developing best practices and guidelines for FF-SIF implementation, quantifying the reduction in total cost of ownership, and quantifying reduced installation costs associated with the technology. The Fieldbus Foundation also has to go through the process of testing devices from suppliers when
they are available to ensure that they meet FF specifications (the Foundation
“check mark” that everyone is familiar with).
ARC expects, however, that once products are available, the adoption and implementation of FF-SIF systems should be accelerated by the fact that many end users are specifying FF-based systems and devices for their large grassroots projects today, so we will not have the same gradual bell curve of acceptance that we saw in the early days of fieldbus. Many systems integrators have also shied away from implementing fieldbus systems because safety systems account for a large portion of the I/O on major projects.
With an FF-SIF system available, it will be increasingly difficult to make that argument. ARC also sees a lot of potential for FF-SIF in existing facilities. There are a number of older safety systems installed in plants today that will require upgrading just as there are a large number of ageing basic process
control systems.
Availability of FF-SIF and its promise of reduced spurious trips, advanced diagnostics, reduced lifecycle and operational costs, and compatibility with existing hardware infrastructures, could provide many end users with the impetus to convert to these systems more rapidly. The large amount of end user support around the Amsterdam demo is a strong indicator that FF-SIF has a strong future.
The ARC Advisory Group has issued a white paper, "Foundation Fieldbus Safety Instrumented Functions Forge the Future of Process Safety," describing Foundation SIF technology, which can be downloaded at the Fieldbus Foundation website (www.fieldbus.org).
Device developmentIn January 2009, the Fieldbus Foundation announced new device development solutions for its Foundation for Safety Instrumented Functions (SIF) technology. This latest SIF release includes:
• The Foundation for SIF final Technical Specification package • SIF Interoperability Test Kit (ITK)• Updated DD Library with SIF function blocks
These solutions support development of interoperable SIF devices for use in a wide range of industrial plant SIF applications
According to the Fieldbus Foundation's product manager-fieldbus products, Stephen Mitschke, the new Foundation for SIF solutions will enable automation equipment suppliers to develop SIF devices incorporating powerful fieldbus diagnostics.
He said, "Plant safety systems can now employ the same rich diagnostic capabilities traditionally offered by Foundation fieldbus technology. These diagnostics are the key to improved process reliability and robustness, as well as increased uptime and fewer spurious alarms."
"Leading automation equipment suppliers are designing a variety of devices to meet the growing market demand for fieldbus-based SIFs. Our developer resources ensure the interoperability of fieldbus equipment in modern safety systems. Certifying agencies such as TUV then provide certification for use of the equipment in safety instrumented systems," Mitschke added.
The Foundation for SIF Technical Specification defines analog input (AI) blocks for fieldbus transmitters and other SIF devices. Future updates to the specification will include digital output (DO) blocks. Within Foundation technology, function blocks contain the information needed for online control functions. Device description (DD) and capability files (CF) provide additional information required for configuration and display purposes.
The Foundation for SIF Interoperability Test Kit (ITK 1.0) is a tool for troubleshooting and debugging devices, and provides all hardware and software required to ensure a manufacturer's complete device interoperability as specified by the Fieldbus Foundation's official registration testing procedure. By using the test kit, device developers can run tests identical to those used by the Foundation before submitting their device for registration.
The Foundation DD Library (Version 3.4) has been updated to include standard device description language (DDL) code for new SIF blocks. With this DD subscription service, device developers have access to a template DDL that makes it easier and less time-consuming to develop DDs to the Foundation fieldbus specification.
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For more information Please visit Honeywell website at www.honeywell.com/ps/sea
Foundation fieldbus technology enables process end users to realize significant CAPEX and OPEX benefits by extending fieldbus benefits into plant safety systems. The Foundation for Safety Instrumented Functions (SIF) protocol has already been approved by TÜV to meet the requirements of IEC 61508 up to, and including, safety integrity level (SIL) 3.
In May 2008, the Fieldbus Foundation conducted a successful end user demonstration of its Foundation for SIF solution at the Shell Global Solutions technology center in Amsterdam, The Netherlands.
The purpose of this live technology demonstration, which attracted process automation end users and equipment suppliers from around the world, was to evaluate Foundation fieldbus-enabled safety valves with partial stroke testing (PST) capability, as well as various pressure, level, temperature and diagnostic devices. The demo also evaluated system integration capabilities with asset management and basic process control system (BPCS) platforms.
The Shell demonstration showed that even in the middle of a partial stroke test the emergency shutdown system could successfully take over and shut down the system during an abnormal situation. Two out of three (2oo3) voting was demonstrated using various fieldbus SIF devices. The system also reacted successfully to a loss of temperature probe, as well as a measurement validation alarm and a diagnostic alarm generated from a dry probe on a level device.
Audun Gjerde of Shell Global Solutions, who conducted the SIF demo at the Amsterdam event, commented, "By implementing Foundation for SIF, Shell expects enhanced diagnostics through a fully integrated asset management system. We also anticipate less testing of final elements thanks to smart testing and diagnostics, as well as online testing and partial stroke testing. This will result in early detection of dangerous device failures-and fewer spurious trips."
He continued, “The added SIF diagnostics will help engineers and maintenance personnel increase the integrity of the plant by ensuring maintenance is performed where and when it is needed. With smart online testing and diagnostics, we will be able to run for longer periods of time without shutting down the plant for testing purposes. We will also save on the cost of adding a second or third device in many cases.”
Successful Foundation fieldbus-based safety shutdown system demonstration at Shell Global Solutions technology center in Amsterdam, May 2008.
Pent-up demand According to an ARC end user survey for safety systems, there is a pent-up demand for Foundation Fieldbus for process safety applications, which was reflected in the survey results. Over a third of the respondents indicated they were willing to use the present Foundation Technology for safety applications.
The difference between the demo of basic fieldbus functionality at Shell many years ago and the recent safety system demo is the high level of end user commitment that is already behind the technology. Most of the large integrated oil companies have already begun large-scale adoption of Foundation Fieldbus technology, and the availability of Foundation Fieldbus based safety systems has been widely anticipated. Shell has stated that they plan to use FF-SIF on their new projects starting in 2011.
But several hurdles must yet be passed before FF-SIF products are available on the market. Aside from product development and approval, future developments from the Fieldbus Foundation and member companies include developing best practices and guidelines for FF-SIF implementation, quantifying the reduction in total cost of ownership, and quantifying reduced installation costs associated with the technology. The Fieldbus Foundation also has to go through the process of testing devices from suppliers when they are available to ensure that they meet FF specifications (the Foundation “check mark” that everyone is familiar with).
ARC expects, however, that once products are available, the adoption and implementation of FF-SIF systems should be accelerated by the fact that many end users are specifying FF-based systems and devices for their large grassroots projects today, so we will not have the same gradual bell curve of acceptance that we saw in the early days of fieldbus. Many systems integrators have also shied away from implementing fieldbus systems because safety systems account for a large portion of the I/O on major projects.
With an FF-SIF system available, it will be increasingly difficult to make that argument. ARC also sees a lot of potential for FF-SIF in existing facilities. There are a number of older safety systems installed in plants today that will require upgrading just as there are a large number of ageing basic process control systems. Availability of FF-SIF and its promise of reduced spurious trips, advanced diagnostics, reduced lifecycle and operational costs, and compatibility with existing hardware infrastructures, could provide many end users with the impetus to convert to these systems more rapidly. The large amount of end user support around the Amsterdam demo is a strong indicator that FF-SIF has a strong future.
The ARC Advisory Group has issued a white paper, "Foundation Fieldbus Safety Instrumented Functions Forge the Future of Process Safety," describing Foundation SIF technology, which can be downloaded at the Fieldbus Foundation website (www.fieldbus.org).
Device developmentIn January 2009, the Fieldbus Foundation announced new device development solutions for its Foundation for Safety Instrumented Functions (SIF) technology. This latest SIF release includes:
• The Foundation for SIF final Technical Specification package • SIF Interoperability Test Kit (ITK)• Updated DD Library with SIF function blocks
These solutions support development of interoperable SIF devices for use in a wide range of industrial plant SIF applications
According to the Fieldbus Foundation's product manager-fieldbus products, Stephen Mitschke, the new Foundation for SIF solutions will enable automation equipment suppliers to develop SIF devices incorporating powerful fieldbus diagnostics.
He said, "Plant safety systems can now employ the same rich diagnostic capabilities traditionally offered by Foundation fieldbus technology. These diagnostics are the key to improved process reliability and robustness, as well as increased uptime and fewer spurious alarms."
"Leading automation equipment suppliers are designing a variety of devices to meet the growing market demand for fieldbus-based SIFs. Our developer resources ensure the interoperability of fieldbus equipment in modern safety systems. Certifying agencies such as TUV then provide certification for use of the equipment in safety instrumented systems," Mitschke added.
The Foundation for SIF Technical Specification defines analog input (AI) blocks for fieldbus transmitters and other SIF devices. Future updates to the specification will include digital output (DO) blocks. Within Foundation technology, function blocks contain the information needed for online control functions. Device description (DD) and capability files (CF) provide additional information required for configuration and display purposes.
The Foundation for SIF Interoperability Test Kit (ITK 1.0) is a tool for troubleshooting and debugging devices, and provides all hardware and software required to ensure a manufacturer's complete device interoperability as specified by the Fieldbus Foundation's official registration testing procedure. By using the test kit, device developers can run tests identical to those used by the Foundation before submitting their device for registration.
The Foundation DD Library (Version 3.4) has been updated to include standard device description language (DDL) code for new SIF blocks. With this DD subscription service, device developers have access to a template DDL that makes it easier and less time-consuming to develop DDs to the Foundation fieldbus specification.
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For more information Please visit Honeywell website at www.honeywell.com/ps/sea
