Easy, flexible, reliable.

Process Safety with SIMATIC Safety Integrated

A safe bet: highly available operation without any weak links

Process engineering, with its predominance of extremely complex sequences, cannot afford to have any weak links in the chain. Downtime and faults may have devastating effects for people, equipment, plants and the environment. To eliminate the source of hazards and minimize risks, you need to have reliable safety technology for your processes that meets even the most stringent demands: the Safety Instrumented System (SIS) of your choice should be easy, flexible and reliable. Easy to implement, operate and maintain. Flexibly adaptable on changed conditions with a high degree of investment protection. Reliable in eliminating risks without stopping the production.

Seamless safety technology ... SIMATIC Safety Integrated is a comprehensive product range of fail-safe, fault-tolerant and highly available applications for the process industry. The Safety Instrumented System (SIS) by Siemens enables early detection of critical signals, processing of those signals within a predefined logic and execution. It offers one of the most integrated systems available today, bridging the gap with regards to engineering and communication tools over other conventional offerings. ... completely integrated into standard automation The SIMATIC S7-400FH automation system provides the right mix of distributed I/Os to ensure maximum safety, fault-tolerance and availability for your applications. In correlation with the SIMATIC PCS 7 process control system, you can realize powerful, flexible solutions for integrated automation and safety applications in one, integrated automation network. Part of Totally Integrated Automation With Totally Integrated Automation, Siemens is the only provider of an integrated range of products, systems and solutions for automation in all sectors of industry from inbound logistics to outbound logistics, from the field level to the manufacturing execution level to the corporate management level. One part of Totally Integrated Automation is SIMATIC Safety Integrated. Something you can rely on For more than 20 years, we have been a reliable industry partner for first-class automation solutions for process safety in a wide range of applications. Typical safety applications include fire and gas, burner management, emergency shutdown and process critical systems. Our solutions are designed for maximum efficiency, enabling you to benefit from remarkable savings potential. Our solutions comply both with applicable national and international standards such as IEC 61508 (to SIL 3) and IEC 61511.

A safe bet: reduced life cycle costs without compromise

You expect a modern Safety Instrumented System (SIS) to consistently reduce the probability of dangerous risks and to reliably execute safety-related operations and functions. In addition, you expect redundant, faulttolerant systems to ensure high-availability processes without downtimes. Just as important is reliable selfdetection of internal faults and a guaranteed safe system state. In the unlikely event of a system fault, the diagnostic tools immediately detect it, and localize it for quick repair. Although reliability is the highest priority, economic aspects of the solutions certainly play a big role in your decision.

Maximum system availability SIMATIC Safety Integrated offers systems with both single and redundant design. Redundant systems provide you with maximum availability for your machines and plants right from the start. Our SIS also ensures minimum unplanned downtimes during operation and, accordingly, minimization of the related costs: the fail-safe modules are completely redundant internally, feature a diversified design and can diagnose internal and external faults quickly and effectively. More flexibility The modular design of SIMATIC Safety Integrated provides a high degree of flexibility for futureoriented plant concepts. For instance, you can unite standard and safety functions on one controller or leave them on separate controllers. Depending on your requirements, the distributed I/O modules can be equipped or expanded to include standard and fail-safe modules either combined in the same station or separately.

Saves costs, space and installation overhead With SIMATIC Safety Integrated, you benefit from the considerable savings potential in different ways. Thanks to the coexistence of standard and fail-safe modules in one station, you can cut down the number of hardware components, save separate wiring and reduce cabinet space. That save on reduces the amount of spare parts you need to have on hand effectively cutting your overall logistics costs. Since you can use the proven PROFIBUS standard for fail-safe communication by proven PROFIsafe profile, you no longer need a separate safety bus. Greatly simplified engineering SIMATIC Safety Integrated makes the engineering much easier. On the one hand, you benefit from integrated data management of standard and fail-safe projects including visualization and diagnostics. On the other hand, you only need one tool for standard and safety tasks. You can configure your safety and standard functions for the SIMATIC S7-400FH using the Continuous Function Chart (CFC) its easier, its more efficient and theres no long training time involved. The Safety Matrix features even more benefits. This easy-to-use configuration tool automatically generates complex, fail-safe programs based on a cause & effects matrix, where the cause and effects are easy to link. That means you can configure your safety logic much faster than before.

Easy integration into the process control system You can connect our innovative Safety Integrated System SIMATIC S7-400FH and SIMATIC ET 200M/S to any distributed control system (DCS). One of the unique features is the integration of fail-safe functions into the SIMATIC PCS 7 process control system. This combination also provides you with a number of benefits: One engineering system for standard and fail-safe applications Homogeneous integration of safety engineering into the automation system (AS) of SIMATIC PCS 7 User-friendly visualization of process values integrated into the operator station (OS) of SIMATIC PCS 7 Automatic integration of safety-related fault messages into the process visualization, with time stamp No complicated handling of data between the DCS and SIS

A safe bet: well-designed and detailed system architecture

SIMATIC Safety Integrated is a first-class Safety Instrumented System solution (SIS) based on innovative and proven products, systems and standards. The highlight: you can easily connect SIMATIC Safety Integrated to any control system already integrated and harmonized with SIMATIC PCS 7.

Internet OPC s

Engineering station

OS clients

Batch client

OS server (redundant) Industrial Ethernet /

SIS SIMATIC Safety Integrated

TV

TV

SIMATIC S7-400FH

PROFIBUS with PROFIsafe profile

Standard and fail-safe SIMATIC ET 200S Standard and fail-safe SIMATIC ET 200M Standard SIMATIC ET 200M

PROCESS FIELD BUS

PROCESS

Single design

SAP R/3

Office LAN Plant information

Ethernet Plant maintenance

t/Intranet server

IT components

Fast Ethernet Batch server (redundant)

Controller Fail-safe, fault-tolerant and highly available SIMATIC S7-400FH configuration as for standard S7-400 Maximum safety level SIL 3 can be met with only one controller Standard and safety functions can be united in one controller or separately

Fast Ethernet

SIMATIC S7-400FH

FH controllers can be set up at separate locations up to 10 km apart Distributed I/O SIMATIC ET 200M with a large number of I/O modules and bit-modular SIMATIC ET 200S NAMUR module of SIMATIC ET 200M for Ex-areas Expandable with standard and fail-safe modules depending on your requirements Fail-safe modules: completely redundant internally and with a diversified design Comprehensive diagnostic functions for detecting internal and external faults

PROFIBUS with PROFIsafe profile

Standard and fail-safe SIMATIC ET 200M Fail-safe SIMATIC ET 200M Standard SIMATIC ET 200M

FIELD BUS

Safety functions included in the fail-safe signal modules Communication Standard PROFIBUS DP with PROFIsafe profile

Redundant design

A safe bet: proven, innovative engineering

We offer you engineering solutions perfectly tailored to your individual requirements. Integration of SIMATIC Safety Integrated into SIMATIC PCS 7: engineering system SIMATIC PCS 7 with the optional Safety Matrix package incl. integrated viewer 4 Connection of SIMATIC Safety Integrated in a conventional Distributed Control System: Continuous Function Chart 1 with the optional Safety Matrix package

Continuous Function Chart (CFC) The proven graphical engineering tool from the Engineering System (ES) of SIMATIC PCS 7 lets you create standard and fail-safe functions. The fail-safe functions are created by simply retrieving and interconnecting TV-certified (German Technical Inspectorate) function blocks from a library. Safety Matrix Our Safety Matrix 2 features an innovative configuration tool for processes which require safety reactions to defined states and can be easily configured based on a cause & effects matrix. The cause & effects analysis is a component of a plants risk analysis. In this context, specification of the safety program also corresponds to the input parameters for the safety matrix 3 . The test specification for the plant is derived from the successful input.

Continuous Function Chart (CFC) or Engineering System (ES) of SIMATIC PCS 7 for configuring standard and fail-safe functionality with official TV-certified function blocks

Configuration of analog or digital causes and digital effects

The benefits of the Safety Matrix at a glance Configuration of safety functions (logic) with the known cause & effects method i. e. based on process events and process reactions Automatic creation of the safetyrelated STEP program Minimization of fault sources thanks to easy and transparent configuration Automatic generation of documentation after safety reviews Shortened configuration times, since no special programming knowledge is required Automatic generation of visualization and user-friendly display of the safety matrix at the operator station of SIMATIC PCS 7
Safety Matrix: Intersections define the link between cause and effects

Automatic management of project versions of the program Easy tracking of changes Straightforward changes to safety functions and easy adaptation of specifications in test mode, as well as bypass, reset and override functions.

User-friendly visualization of the Safety Matrix at the operator station (OS) with SIMATIC PCS 7

A safe bet: references in the process industry

Whether its refineries or petrochemicals, oil and gas, chemicals, pharmaceuticals: based on our sound knowhow and our comprehensive experience, we have already implemented a wide array of turnkey solutions in the process safety segment. These solutions have proven their worth in everyday use around the world.

Oil and gas: Statoil offshore platform, Norway Statoil, the largest Norwegian petroleum corporation, relies on a combination of fire and gas alarm systems and emergency shutdown systems to reliably meet all the critical safety requirements for its unmanned Huldra offshore oil platform in the North Sea. One reason for this: the previously installed SIMATIC S5 has a proven record of past reliability. The solution 5 SIMATIC S7-400FH controllers 3000 fail-safe inputs and outputs via SIMATIC ET 200M Plant configuration The project marked the beginning of a new generation of automation controllers with integrated safety engineering at Statoil. Since then, 20 more platforms have been equipped with SIMATIC S7-400FH. Statoil further leveraged its cost savings by reusing the user programs on all the platforms. Chemicals: production of plant protection products at Bayer in Dormagen, Germany At its new multipurpose plant in Dormagen, it was especially important for Bayer CropScience AG to establish an integrated system with SIMATIC PCS 7 from the field level to the ERP level (SAP). Bayer decided on a control system solution with integrated safety engineering for 35 process engineering plants, 240 subsystems and 4500 measuring points. The solution SIMATIC PCS 7 process control system with SIMATIC Safety Integrated 53 SIMATIC S7-400FH controllers 1000 fail-safe inputs and outputs via SIMATIC ET 200M Plant configuration SIMATIC Safety Integrated has led to a reduction in engineering costs over the entire life cycle of the new multipurpose plant. Thanks to the high degree of flexibility, production can be adapted to changing requirements much more easily and quickly. Based on assignment of controllers according to specific subsystems, i. e. one controller per subsystem, it is much easier to perform maintenance work and modifications.
Bayer in Dormagen, Germany

Statoil offshore platform, Norway

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Refinery: Shell Deutschland Oil in Heide When modernizing and restructuring its refinery in Heide, Shell Deutschland Oil was basically pursuing the following objectives: greater efficiency and products that meet the requirements of the market now and in the future. The plant solution needed to include a combination of both standard and fail-safe distributed I/O modules in an automation system that is highly available and at the same time fail-safe. The solution SIMATIC PCS 7 process control system with SIMATIC Safety Integrated 22 SIMATIC S7-400FH controllers 25 % of entire distributed I/O are fail-safe inputs and outputs via SIMATIC ET 200M Plant configuration SIMATIC Safety Integrated is a winning solution from any perspective as a secure investment, for integration, scalability, user friendliness and its modular design. The openness of SIMATIC PCS 7 enables easy vertical integration of the ERP level via standardized interfaces. In addition, the modernized plant can be configured, diagnosed and maintained much more efficiently and quickly right to the field level online via PROFIBUS. Refinery: Repsol YPF in Tarragona, Spain Another project where Siemens has proven its sector expertise was the automation of the new hydrocracker for Repsol YPF at its refinery in Tarragona, Spain. The hydrocracker itself refines an impressive daily throughput of 24,000 barrels of petroleum, turning it into high-quality products. The demands on the SIS were just as impressive. The tasks include locking the two ovens, motorized controllers and regulation of the tank fill level as well as emergency shutdown for five compressors for controlling the ventilation flue and the ovens. The solution SIMATIC PCS 7 process control system with SIMATIC Safety Integrated 2 SIMATIC S7-400FH controllers 1900 fail-safe inputs and outputs via SIMATIC ET 200M
Repsol YPF in Tarragona, Spain

Shell Deutschland Oil in Heide

Plant configuration The two SIMATIC S7-400FH controllers ensure that the plant is operating in the green range at all times. With the new hydrocracker, Repsol YPF was able to increase its production of gasoline, diesel and other high-quality petrochemical products considerably. Of course, the fuels from Tarragona also comply with the new environmental guidelines of the EU.

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You want to know more? You can find more information on the Internet:
SIMATIC Safety Integrated: www.siemens.com/fh-cpu SIMATIC PCS 7: www.siemens.com/simatic-pcs7 Safety Integrated: www.siemens.com/safety Totally Integrated Automation: www.siemens.com/totally-integrated-automation Download and order info material: www.siemens.com/simatic/printmaterial SIMATIC Partners: www.siemens.com/automation/partners Order online A&D Mall: www.siemens.com/automation/mall Service & Support: www.siemens.com/automation/service&support
Subject to change without prior notice 04/04 | Order No. E20001-A550-P210-X-7600 | DISPO 06303 | 41C8516 MK.AS.FH.52.4.03 WS 04042.5 | Printed in Germany | Siemens AG 2004

Siemens AG Automation and Drives

SIMATIC is a registered trademark of Siemens. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners. The information provided in this brochure contains merely general descriptions or performance characteristics, which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

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