1. business and industrial
2. automation
3. robotics

Product Group Safety
Independent High Integrity (HI)
Technical Overview
Table of Contents

Independent HI Offering

AC800M High Integrity

Control Builder Safe

Certification

Diversity vs. Architecture

Use of Redundancy

Security

Connectivity & Interfacing

Systematic Capabilities
© ABB Group
January 12, 2017 | Slide 2

Engineering

Maintenance
Independent High Integrity
Safety Product Offering

Independent HI has the exact same certified components
as the System 800xA High Integrity safety system

Does not include functionality related specifically to process
control (i.e. HMI or Operations)

Control Builder Safe includes those items required for
certified safe operations

Perfect solution for many
industries:
© ABB Group
January 12, 2017 | Slide 3

Great for industrial
applications:

Oil & Gas

Emergency Shutdown

Petrochemical

Relay Interlock

Chemical

Remote Terminal Units

Pulp & Paper

Burner Management

Power

High Integrity Pressure
Protection
Independent High Integrity
Safety Product Offering




HI Hardware

TUV certified SIL 3
controller (PM865/SM811)

24 VDC DC I/O and 4-20
ma Analog inputs
Control Builder Safe

Engineering

IEC1131 languages

Access control and override
control

Certified Libraries
Connectivity and Interfacing

ABB Control systems

3rd party software and
control systems
Diagnostics
© ABB Group
January 12, 2017 | Slide 4
Small Independent HI system with engineering and DCS
Certificates
High Integrity ABB Safety Certificates
Product Safety
Certificate

Development Department
Safety Certificate
TÜV certification for the hardware, software and
development organization
© ABB Group
January 12, 2017 | Slide 5
Safety Manual
Certificates
AC800M High Integrity – Meets Industry Standards
© ABB Group
January 12, 2017 | Slide 6

AC800M HI Controller – SIL 13 / CAT PLe 1-4 certified

S800 Safety I/O (AI, DI, DO) –
SIL 1-3 / CAT PLe 1-4 certified

I/O Communication – SIL 1-3 /
CAT PLe 1-4 certified

System certified to IEC61508,
IEC61511 / ISA84,
EN54/NFPA72, NFPA85,
NFPA86

Additional I/O and
communication modules –
certified as interference-free*
(*Listed in safety manual)
Diversity vs. Architecture
1st Generation Logic Solver Architectures
• Duplex
• 1oo2D
• Triplex
•
2oo3
• Quad (Bi-Duplex)
• 2oo4D
Independent HI – Standalone Architecture
Diverse Architecture, Diverse Implementation
CB
AC800M HI
SIL3
PM
SIL3
SM

The SIL 3 High Integrity controller has
parallel processing paths based on
diverse technology

Integrity voting between paths
compliments the built in active
diagnostics

Controller (PM) and Safety Module
(SM) 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
© ABB Group
January 12, 2017 | Slide 9
Independent High Integrity
Application Execution
CEX Bus
ModuleBus
I/O-Data+CRC
1131
SIL3
1131
SIL3
Superv. Logic
Superv. Logic
Safety Module
SM
I/O-Data
I/O-Data
Processing Module
PM
Diverse Exec.
I/O-Data
Diverse Exec.
I/O-Data+CRC
Safety I/O
Parallel diverse execution
allows a hardware fault
tolerance of 1 for SIL3
applications
HFT = 1 (SIL 3 Execution)
SFF
Hardware fault tolerance
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
IEC 61508-2, Table 3
© ABB Group
January 12, 2017 | Slide 10
Independent High Integrity
Safe Failure Fraction (SFF)

Modern design techniques allows the AC800M HI achieve near
100% diagnostics coverage without needing to resort to use HFT
factors to reduce PFD
SFF
Hardware fault tolerance
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
IEC 61508-2, Table 3

AC800M HI controller does not rely on voting schemes like TMR
to increase the safety integrity
© ABB Group
January 12, 2017 | Slide 11
S880 High Integrity I/O Family
Features with Embedded Diversity

Single and Redundant
configuration

Hot Insertion and Hot Swap
in redundant configuration

G3 Coating

EX certified – Zone 2, Class
1 according to US standard
© ABB Group
January 12, 2017 | Slide 13

Embedded Diversity

Two diverse execution
paths based on different
hardware technology

Both MCU and FPGA

Each individual single IO
module has an internal
1oo2 architecture
Use of Redundancy
Meet SIL 3 Criteria without Redundancy
Single Configuration
SM811
© ABB Group
January 12, 2017 | Slide 15
PM865
TB840
Single I/O AI8880, DI880 and DO880
AC800M High Integrity
Redundant Controller Configuration for Availability

AC800M High Integrity offers
availability figures comparable to or
better than typical TMR systems


4 CPUs
© ABB Group
January 12, 2017 | Slide 16
Availability up to 99.9999%
Redundancy and switch-over to
stand-by unit allow continuous
operation without time restriction upon
failure of one of the redundant
modules
Security
Security
Safety Module Security and Indication
C
C
P
P
“Reset all forces”
© ABB Group
January 12, 2017 | Slide 18
Hot Insert

Reset All Forces – Enable a quick reset of all
forces in the controller

Access Enable – Activates the access enable
function

Hot insert – Initiates hot insertion of SM811
(in redundant configuration)

Force Indicator – Active if one or more
signals are in force

System Alarm Indicator – Active if there are
one or more system alarms
Force
Indicator
System
Alarm
Independent High Integrity
System Security And Embedded Firewalls
*



Based Windows security model with:

Configurable restrictions per user

Auditing

Authentication and Digital signature
Functions for protection of SIL classified
applications in AC800M HI Controllers

SIL Access Control and Authorization

Force Control / Override Control / Bypass
Management

Confirmed Online Write / Confirmed
Operation
Embedded firewalls and confirmation
procedures protect the SIL application from
inadvertent / accidental control actions
* Possible via Remote Desktop to Engineering Station
© ABB Group
January 12, 2017 | Slide 19
Security
Roles & Responsabilities

Users can be assigned with
different permissions
according to their
responsabilities

Restriction of access to the
SIS (engineering and
operation from Engineering
Station)

High flexibility
© ABB Group
January 12, 2017 | Slide 20
Security
Audit Trail



Enables audit of all operator
and engineering actions
Possible to disabled during
commissioning

Audit log contains:

Date and time for the operation

Node from which the operation
was performed

User name of the individual
performing the operation

Type of operation

Object, property or aspect
affected by the operation
Audit actions examples
© ABB Group
January 12, 2017 | Slide 21

Configuration changed

Signal forced

Download

Reserved/Released
Connectivity & Interfacing
Independent High Integrity
Connectivity and Interfacing


Available protocols…

Safety Peer to Peer

OPC

ABB protocols

Modbus TCP *

RS232 *
..to connect to..

AC800M HI controllers

Process panels

ABB or 3rd party DCS &
PLC

3rd party HMI software
© ABB Group
January 12, 2017 | Slide 23
* Planned for a future release
Independent High Integrity
Communication Interfaces

© ABB Group
January 12, 2017 | Slide 24
Communication certified
“interference free”

Not intended for a
safety critical functions

All certified interference
free modules listed in
the ABB Safety Manual
Freelance and Independent High Integrity (HI)
Solution Example

Modbus


Essential Automation Freelance System:

One AC 900F controller to process
approximately 400 I/O signals,

One engineer station combined with
operator station

S700 I/O or S800 remote I/O or S900 I/O
contact main controller via Profibus DP

Redundant Ethernet (Optional)
Independent High Integrity (HI) SIL3/SIL2
Application

1 AC 800M HI controller to process 350 I/O
signals

S800 HI I/O

One Control Builder Engineering Station

Redundant Ethernet (Optional)
Connectivity and Interfacing

OPC (preferred for SIS supervision)

Alternative communication module CI853
(RS-232) via Modbus to interface to
Freelance AC 900F Controller
Systematic Capabilities: Engineering
Engineering
SIL Compliant Application Environment

Engineering tool automatically limits
user configuration choices to ensure
integrity

Safety functions protect and control
download to the process and runtime
environment


Download is prevented unless all
SIL requirements are met
Embedded firewall mechanisms
include:

CRC protection on different levels

Double code generation with
comparison

Compiler with revalidation
© ABB Group
January 12, 2017 | Slide 27
Engineering
Compiler Restrictions

The compiler warns and / or prevents the engineer from designing
dangerous code

For example complex code structures, loops etc

The compiler checks that all restrictions and rules necessary to
achieve the intended SIL of the application are adhered to

An error is reported when a rule is violated and the attempted
download to the controller is blocked
© ABB Group
January 12, 2017 | Slide 28
Engineering
On-line changes

Online changes can be
downloaded to the
controller without interfering
with the running process

FB/CM parameters
(e.g. trip limit)

Hardware settings (e.g.
ISP value)

Logic

Downloads are protected by
the “Access enable”
function

Re-authentication can be
configured to ensure that
the user is authorized

© ABB Group
January 12, 2017 | Slide 29
This is also recorded in
the audit trail
Engineering
Difference Report

Reports the differences between the project running in the
controller and the project in the Control Builder M

Presented before download to the controller

Changes may be rejected (in which case the download is
cancelled)

Each difference report is saved and stored automatically
and can be reviewed at any time

This, together with audit trail functionality and more,
provides a well documented and traceable history
© ABB Group
January 12, 2017 | Slide 30
Engineering
Certified Libraries
© ABB Group
January 12, 2017 | Slide 31

System

AlarmEventLib

BasicLib

FireGasLib

MMSCommLib

ProcessObjBasicLib

ProcessObjExtLib

SerialCommLib

SignalBasicLib

SignalLib

SignalSupportLib

SupervisionBasicLib

SupervisionLib
Engineering
SIL Applications
SIL2
SIL3
Supported Languages
Function Block
X
X
Structured Text
X
X
Sequential Function
Chart
X

SIL level can be configured
independently by application

Supported languages

Control Modules

IEC 61131-3
© ABB Group
January 12, 2017 | Slide 32
Systematic Capabilities: Maintenance
Maintenance
Force Control

The AC 800M HI supports supervision and
control over the forces in SIL classified
applications

Each SIL application has a configurable
maximum number of allowed forces (0 by
default)

Offers easy overview of the current status of the
SIS and the ability to quickly restore all safety
functions to full functionality

Hardware signals


Reset All Forces (Input)

Any Force Active (Output)
ForcedSignals FB
© ABB Group
January 12, 2017 | Slide 34

Force supervision and reset

SIL3 certified
Maintenance
Inhibit
© ABB Group
January 12, 2017 | Slide 35

Avoid spurious trips during
maintenance procedures

Inhibit action limits

Alarms will be shown to the operator
but no safety action will be taken

Configurable automatic reset of all
overrides with the Maintenance
Engineer confirmation
Safety Product Offering
Independent High Integrity




HI Hardware

TUV certified SIL 3
controller (PM865/SM811)

24 VDC DC I/O and 4-20
ma Analog inputs
Control Builder Safe

Engineering

IEC1131 languages

Access control and override
control

Certified Libraries
Connectivity and Interfacing

ABB Control systems

3rd party software and
control systems
Diagnostics
© ABB Group
January 12, 2017 | Slide 36
Small Independent HI system with engineering and DCS
Safety Product Offering
Conclusion

ABB’s High Integrity safety offerings are TUV certified to
the most recent version of the standards (IEC61508
Edition 2)

We rely on diversity, not architecture, to meet SIL


i.e. you aren’t paying for unnecessary redundancy
Our architecture is very flexible, you can have:

Integrated (same hardware, network etc.)

Combined (same controller)

Single or redundant controller configuration

Interfaced with any HMI or DCS (Independent HI)

High Integrity is accepted (approved) by most major Oil &
Gas companies

ABB has expertise, support and partners all over the
world
© ABB Group
January 12, 2017 | Slide 38