Introduction to ProsafeRS

YOKOGAWA Safety System

 ProsafeRS is the Safety System of YOKOGAWA

What is a safety system ?

?
A safety system is an Independent system that leads to a
Predetermined safe state in case that the process
runs out of control
What is a meant by an Independent system ?

SIF LOOP
System Architecture
 This is how a Prosafe looks in the Cabinet

Safety control Unit (SCU) or Node1

ESB redundant module for inter domain communication

SCU FAN unit

KS1 cables
Note:
in this System, all the I/O
Node 2 cards are connected to the
terminal boards in each
marshalling cabinet via
dedicated KS1 cables

Node 3
 Redundancy
• All hardware should be redundant in a safety system.
• Different hardware topologies (i.e. 1oo2, 1oo3) are used in field Instruments to achieve safety and availability
• In ProsafeRS- CPU, PSU, I/O modules, even Network will be Redundant
• In Vnet-IP, 2 different network system Bus1 & Bus2 will be utilized for redundancy

SIL certification (Safety Integrity Level)

• The most important standards for functional safety are IEC 61508 & 61511
• All hardware should be safety certified, that includes field instruments also .
• SIL certification is given by TUV.
• Prosafe can support up to SIL 4, However it depends on the Demand rate, Consequences etc
• SIL level can predict Average Probability of failure on demand(PFD)

SIL Level Average probability of failure on demand Risk reduction factor (1/PFD)
4 < >10000
3 ≥ 1000-10000
2 ≥ 100-1000
1 ≥ 10-100
Redundancy for Sensor Redundancy for final elements
 Difference between normal PLC/DCS and Safety System(ProsafeRS)
Normal PLC/DCS
High flexibility needed to develop and maintain
(complex) control and automation applications
Configuration changes can be done Online
During the failure of the control system, state of
outputs are unpredictable
Regular testing is not required except for some
backup/ redundant parts
Control system Runs 24/7 all the time
Not a fail safe design
Safety PLC
Fixed functionality, carefully minimized during design
Complex procedure are Involved in making any
changes
Output states are predictable during the functional
failure of the system
Complex procedures are followed to test the system
hardware
Safety system is always on Hot standby
Fail safe Design
Introduction to the Software

Prosafe-RS Workbench is the software program used to

configure the Prosafe system, the software also provides the user
with the ability to:

• Edit a Project
• View and Update Variables
• Perform Trouble shooting
• Produce documentation

The Languages are available for configuring the Prosafe-RS

system:

1. Functional Block diagram

2. Ladder
3. Structure Text