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5.1 Planning; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s ....................................................................... 295.2 Planning; Product-Related C<strong>on</strong>diti<strong>on</strong>s ............................................................................... 305.3 Programming; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s ................................................................ 305.4 Programming; Product-Related C<strong>on</strong>diti<strong>on</strong>s........................................................................ 305.5 Communicati<strong>on</strong>; Product-Related C<strong>on</strong>diti<strong>on</strong>s .................................................................... 315.6 Special Operating Modes; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s ............................................. 315.7 Special Operating Modes; Product-Related C<strong>on</strong>diti<strong>on</strong>s ..................................................... 315.8 Fire Detecti<strong>on</strong> and Alarm Installati<strong>on</strong>s; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s .......................... 326 CERTIFICATE NUMBER ..................................................................................................... 33Revisi<strong>on</strong>Versi<strong>on</strong> Status Date Author SW ver. HW ver. ChangedchaptersReas<strong>on</strong> of change0.1 2012-11-27 M.Braun1.0 final 2013-02-05 M.BraunTable 1: Revisi<strong>on</strong>71.02 R710.2 Old andinvalidstandardshave beenremovedBased <strong>on</strong> SH99495CRevisi<strong>on</strong> 7.10, 2011-03-1471.02 R710.2 Review <strong>com</strong>ments addedTÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 3 of 33


1 Target of Evaluati<strong>on</strong> (ToE)In 30-Aug-2012 the <strong>com</strong>pany H<strong>on</strong>eywell Safety Management Systems assigned TÜV SÜD for recertifyingof the Fail-Safe C<strong>on</strong>troller System Family FSC Versi<strong>on</strong> 710.x according to SIL 1-3 ofEN 61508:2001 series and IEC 61511.The Fail-Safe C<strong>on</strong>troller System Family FSC Versi<strong>on</strong> 710.x is a fail-safe programmable c<strong>on</strong>troller(PLC) suitable in particular for safety-related applicati<strong>on</strong>s requiring approval and applicati<strong>on</strong>s not requiring approval but with a high risk potential(e.g. c<strong>on</strong>trol or protecti<strong>on</strong> systems for chemical processes or fire detecti<strong>on</strong> and alarmsystems).The Certificati<strong>on</strong> <str<strong>on</strong>g>Report</str<strong>on</strong>g> SH99495C revisi<strong>on</strong> 7.10 of 14 thCertificati<strong>on</strong> <str<strong>on</strong>g>Report</str<strong>on</strong>g>.March 2011 is substituted by thisCentral Part I/O c<strong>on</strong>figurati<strong>on</strong> CPU type Architecture Votingc<strong>on</strong>figurati<strong>on</strong>Single Single 10020/1/1 or10020/1/2 (QPM)RedundantSingle, redundant,single andredundant10002/1/2 or10012/1/210020/1/1 or10020/1/2 (QPM)10002/1/2 or10012/1/2DMR1oo1DQMR1oo2D(QPM – Quad Processor Module, QMR – Quadruple Modular Redundant,DMR – Dual Modular Redundant)Table 1: FSC architectures1oo21oo1D2oo4D1oo2DTÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 4 of 33


2 System overview2.1 Descripti<strong>on</strong>The Fail-Safe C<strong>on</strong>troller System Family FSC Versi<strong>on</strong> 710.x is an integrated safety soluti<strong>on</strong>splatform, forms the basis for functi<strong>on</strong>al safety, securing operati<strong>on</strong>s pers<strong>on</strong>nel, plant equipmentand envir<strong>on</strong>ment as well as ensuring optimum availability for plant operati<strong>on</strong>s.Based <strong>on</strong> Quadruple Modular Redundant (QMR) technology, FSC Versi<strong>on</strong> 710.x supports a widerange of high integrity process c<strong>on</strong>trol and safety functi<strong>on</strong>s including: High-integrity process c<strong>on</strong>trol Burner/boiler management systems Process safeguarding and emergency shutdown Turbine and <strong>com</strong>pressor safeguarding Fire and gas detecti<strong>on</strong> systems Pipeline m<strong>on</strong>itoring.FSC Versi<strong>on</strong> 710.x provides a dual redundant fault tolerant c<strong>on</strong>troller for safety and shutdownapplicati<strong>on</strong>s <strong>on</strong> the TPS system's Universal C<strong>on</strong>trol Network (UCN). These safety functi<strong>on</strong>s areintegrated into the architecture to support unified operati<strong>on</strong>s and c<strong>on</strong>trol, while at the same timeproviding the ability to isolate emergency shutdown (ESD) functi<strong>on</strong>s from process c<strong>on</strong>trolstrategies <strong>on</strong> a separate safety network.The Fail Safe C<strong>on</strong>troller can be supplied in a number of architectures, each with its owncharacteristics and typical applicati<strong>on</strong>s. Table 1 above provides an overview of the availablearchitectures. The system can be c<strong>on</strong>figured in a number of different basic architectures (1oo1D,1oo2D, QMR) depending <strong>on</strong> the requirement class of the process, the availability required andthe FSC hardware modules used. This also means that field signals can be handled in multiplevoting schemes (1oo1, 1oo1D, 1oo2, 1oo2D, 2oo4D).The certified system en<strong>com</strong>passes the hardware modules listed below (see chapter 2.1.3 and2.1.4) as well as the corresp<strong>on</strong>ding operating system with the specified software functi<strong>on</strong>s.2.1.1 Test specimenSee Table 1.2.1.2 Functi<strong>on</strong>al block diagramSingle Central Part and Single I/O (1oo1D, DMR) architecture has a single Central Part and singleinput and output (I/O) modules. No redundancy is present except as built into those moduleswhere redundancy is required for safety (memory and watchdog).TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 5 of 33


Figure 1: Single Central Part, single I/OThe next FSC architecture has redundant Central Parts and single input and output (I/O)modules. The processor is fully redundant, which allows c<strong>on</strong>tinuous operati<strong>on</strong> and bump less(zero-delay) transfer in case of a Central Part failure.Figure 2: Redundant Central Parts, single I/OThis FSC architecture has redundant Central Parts and redundant input and output (I/O) modules(OR functi<strong>on</strong> <strong>on</strong> outputs). The processor and I/O are fully redundant, which allows c<strong>on</strong>tinuousoperati<strong>on</strong> and bump less (zero-delay) transfer in case of a Central Part or I/O failure.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 6 of 33


The Quadruple Modular Redundant (QMR) architecture with 2oo4D voting is an evoluti<strong>on</strong> of theproven 1oo2D c<strong>on</strong>cept. The QMR architecture with 2oo4D voting is based <strong>on</strong> dual-processortechnology, and is characterized by a high level of diagnostics and fault tolerance.Figure 5: QMR architecture2.1.3 Safety-Related ModulesThe certified versi<strong>on</strong> of the operating system supports the following tested modules within theapproved c<strong>on</strong>figurati<strong>on</strong>s in safety-related applicati<strong>on</strong>s:Module Number10001/1/1CC10001/R/1CC10002/1/2CC10012/1/2CC10020/1/1CC10020/1/2CC10004/./.CC10014/./.CC10005/1/1CC10007/1/1CC10024/./.CC10100/1/1 and 10100/2/1and FC-IO-0001Module Descripti<strong>on</strong>Vertical bus driverVertical bus driver (relay)Central processing unit (EPROM memory)Central processing unit (FLASH memory)Quad processor module -QPM- (Flash memory)Quad processor module -QPM- (Flash memory)Communicati<strong>on</strong> module (EPROM memory)Communicati<strong>on</strong> module (EPROM, FLASH memory)Watchdog moduleSingle bus driverEnhanced Communicati<strong>on</strong> module (EPROM, FLASH memory)Horiz<strong>on</strong>tal bus driverTÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 8 of 33


Module Number10101/1/1 and 10101/2/1and FC-SDI-1624Module Descripti<strong>on</strong>16 channel digital input module 24 VDC10101/1/2 and 10101/2/2 16 channel digital input module 60 VDC10101/1/3 and 10101/2/3and FC-SDI-164816 channel digital input module 48 VDC10102/1/1 4 channel analog input module for n<strong>on</strong>-redundant systems10102/1/2 and 10102/2/1and FC-SAI-041010105/2/1 andFC-SAI-1620m10106/2/1 andFC-SDIL-160810201/1/1 and 10201/2/1and FC-SDO-082410205/1/1 and 10205/2/1and FC-SAO-0220m4 channel analog input module for redundant systems and n<strong>on</strong>redundantsystems16 channel high-density analog input module16 channel line-m<strong>on</strong>itored digital input module with earth fault m<strong>on</strong>itor8 channel digital output module 24 VDC2 channel analog output module10212/1/1 8 channel digital output module 24 VDC(4 channel fail-safe, 4 channel n<strong>on</strong>-interacting)10213/1/1 and 10213/2/1and FC-SDO-041104 channel digital output module 110 VDC10213/1/2 and 10213/2/2 4 channel digital output module 60 VDC10213/1/3 and 10213/2/3and FC-SDO-04484 channel digital output module 48 VDC10214/1/2 3 channel digital output module 220 VDC10215/1/1 and 10215/2/1and FC-SDO-042410216/1/1 and 10216/2/1and FC-SDOL-042410216/2/3 andFC-SDOL-044810302/1/1 and 10302/2/1 Watchdog repeater4 channel digital output module 24 VDC4 channel digital output module 24 VDC with loop-m<strong>on</strong>itoring4 channel digital output module 48 VDC with loop-m<strong>on</strong>itoring10305/1/1 16 channel analog input c<strong>on</strong>verter10311/2/1 Dual key switch moduleFTA-T-02FC-TSDO-0824FC-TSAI-0410FC-TSHART-1620mFC-TSAO-0220mFTA-T-05FC-TSDO-0424FTA-T-06Fail-safe digital output FTA (24/48/60 VDC, 24 channels)Fail-safe digital output FTA (24 Vdc, 8 channels)Fail-safe analog input FTA (4 channels)Fail-safe 0(4)-20 mA analog input FTA with HART interface(16 channels)Fail-safe analog output FTA (0(4)-20 mA, 2 channels)Fail-safe digital output FTA (24 VDC, 12 channels)Fail-safe digital output FTA (24 Vdc, 4 channels)115 / 230 VAC digital input FTA Fail-Safe (potential free input c<strong>on</strong>tacts)TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 9 of 33


2.1.5 Mechanical and electrical partsThe mechanical and electrical parts of the FSC Fail-Safe C<strong>on</strong>troller System such as cabinetenclosure, backplanes, buses and system interc<strong>on</strong>necting cables are described in the currentversi<strong>on</strong> of the "Fail Safe C<strong>on</strong>trol Hardware Manual".2.1.6 Safety-Related Software Functi<strong>on</strong>sThe certified versi<strong>on</strong> of the operating system supports the following tested software functi<strong>on</strong>s insafety-related applicati<strong>on</strong>s: Reading and generating digital and analogue input and output signals Processing timer and counter data Processing the user program in functi<strong>on</strong> block mode Analogue value processing Calculati<strong>on</strong> functi<strong>on</strong>s including floating point functi<strong>on</strong>s User-defined functi<strong>on</strong> blocks Equati<strong>on</strong> blocks Communicati<strong>on</strong>, see chapter2.6.1 Safety-Related Communicati<strong>on</strong> (FSC Protocol) and2.6.2 Safety-Related Communicati<strong>on</strong> (RKE 3964R Protocol)2.1.7 Tested, n<strong>on</strong>-interacting Software Functi<strong>on</strong>sThe certified versi<strong>on</strong> of the operating system supports the following tested, n<strong>on</strong>-safety-related butn<strong>on</strong>-interacting software functi<strong>on</strong>s: Processing of multiplexed input / output signals Alarm sequences PID algorithm Sequence of event recording (SER) Communicati<strong>on</strong>, see chapter 2.6.3 N<strong>on</strong>-Safety-Related Communicati<strong>on</strong> Real Time Clock (RTC, DCF)TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 12 of 33


2.2 Certified System C<strong>on</strong>figurati<strong>on</strong>sFor safety-related operati<strong>on</strong> of the FSC Versi<strong>on</strong> 710.x, a c<strong>on</strong>figurati<strong>on</strong> in accordance with theSafety Integrity Level as per the following table shall be selected.Quad processor module 10020/1/1 and 10020/1/2 (dual processor):SystemSafety IntegrityLevelNumber of centralpartsMinimum numberof Bus Systems(Note 2, VBD10001/x/1)System resp<strong>on</strong>sein the event offaults, i.e. internalfault c<strong>on</strong>diti<strong>on</strong>sattributable to acentral part(Note 3)single CP -single I/O(DMR, 1oo2 voting)redundant CP -single I/O(QMR, 2oo4D voting)SIL 1 – 3 SIL 1 – 3 SIL 1 – 31 2 21 1System shutdownShutdown of defectivecentral part andc<strong>on</strong>tinued operati<strong>on</strong> forunlimited period usingintact central part(Note 1).redundant CP -redundant I/O(QMR, 2oo4D voting)2Shutdown of defectivecentral part andc<strong>on</strong>tinued operati<strong>on</strong> forunlimited period usingintact central part(Note 1).TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 13 of 33


SystemSystem resp<strong>on</strong>sein the event offailure of fail-safeinput modules(Note 3)System resp<strong>on</strong>sein the event offailure of fail-safeoutput modules(Note 3)single CP -single I/O(DMR, 1oo2 voting)Defective digital inputsare read as “0 signal”and in the case ofanalog inputs, thec<strong>on</strong>figured minimumlimit is used."System shutdown,process group shutdownor alarm” shall beprogrammed.Depending <strong>on</strong> thelocality of the fault, thesystem resp<strong>on</strong>ds asfollows: Group shutdown ofthe channelc<strong>on</strong>cerned withc<strong>on</strong>tinued operati<strong>on</strong>for a period of timedefined by themanufacturers PFDcalculati<strong>on</strong> for aspecific system of thechannel c<strong>on</strong>cerned or System shutdownredundant CP -single I/O(QMR, 2oo4D voting)Defective digital inputsare read as “0 signal”and in the case ofanalog inputs, thec<strong>on</strong>figured minimumlimit is used."System shutdown,process group shutdownor alarm” shall beprogrammed.Depending <strong>on</strong> thelocality of the fault, thesystem resp<strong>on</strong>ds asfollows: Group shutdown ofthe channelc<strong>on</strong>cerned withc<strong>on</strong>tinued operati<strong>on</strong>for a period of timedefined by themanufacturers PFDcalculati<strong>on</strong> for aspecific system or System shutdownredundant CP -redundant I/O(QMR, 2oo4D voting)The input signalsrecognized as defective(set to "0" for digitalinputs and minimumlimit for analog inputs )are overwritten by thecorrect input signalsfrom the other centralpart and an alarm isgenerated."System shutdown,process group shutdownor alarm” shall beprogrammed.Depending <strong>on</strong> thelocality of the fault, thesystem resp<strong>on</strong>ds asfollows: Group shutdown ofthe channelc<strong>on</strong>cerned withc<strong>on</strong>tinued operati<strong>on</strong>for a period of timedefined by themanufacturers PFDcalculati<strong>on</strong> for aspecific system or Shutdown of theaffected central partC<strong>on</strong>tinued operati<strong>on</strong> forunlimited period of timeusing intact central partTable 4: Quad processor module 10020/1/1 and 10020/1/2 (dual processor)Note 1: Faults in redundant central parts, which are detected and localised by self-tests result insingle-central part operati<strong>on</strong> with an unlimited time period. The mode of operati<strong>on</strong>; singleor redundant does not influence the coverage of self-tests. The self-test interval is notextended for single-central part operati<strong>on</strong>. The self-test interval shall be less than thefault tolerance period of the process (PST).Note 2: Multiple VBD Bus systems may be used for expansi<strong>on</strong> and I/O segregati<strong>on</strong>.Note 3: For detailed Informati<strong>on</strong> see the current versi<strong>on</strong> of the FSC Safety ManualCentral processing unit 10002/1/2 and 10012/1/2 (single processor):TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 14 of 33


SystemSafety IntegrityLevelNumber of centralpartsMinimum numberof Bus Systems(Note 6)(VBD 10001/x/1)System resp<strong>on</strong>sein the event oflocalisable faults,i.e. internal faultc<strong>on</strong>diti<strong>on</strong>sattributable to acentral part(Note 5)System resp<strong>on</strong>sein the event of I/O<strong>com</strong>paris<strong>on</strong> errors(n<strong>on</strong>-localisable)Input <strong>com</strong>paris<strong>on</strong>single CP -single I/O (1oo1D)redundant CP -single I/O (1oo2D)SIL 1 - 3 SIL 1 - 2 SIL 1 - 31 2 21 1 2System shutdownredundant CP -redundant I/O (1oo2D)SIL 1 - 2:Shutdown of defective central part and c<strong>on</strong>tinuedoperati<strong>on</strong> for unlimited period using intact centralpart.SIL 3:Possible system resp<strong>on</strong>se: Shutdown of defective central part and singlechanneloperati<strong>on</strong> for a period of time defined bythe manufacturers PFD calculati<strong>on</strong> for a specificsystem.(Note 4)System shutdown can be programmed bymeans of user program.In the event of input signals recognised asinc<strong>on</strong>sistent by <strong>com</strong>paris<strong>on</strong>, the system switchesto the safe c<strong>on</strong>diti<strong>on</strong> of the affected input andindicates this by a system flag.The fault resp<strong>on</strong>se "System shutdown, processgroup shutdown or alarm” shall be programmed.Or if the process is c<strong>on</strong>tinuously m<strong>on</strong>itored by anoperatorAND the process safety time is sufficiently l<strong>on</strong>g toinsure manual shutdownAND the operator has sufficient means to m<strong>on</strong>itor andshutdown the process independent of the FSCsystemAND the fault is annunciated by fail-safe meansmanual reacti<strong>on</strong> and shutdown is permissible.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 15 of 33


SystemSystem resp<strong>on</strong>sein the event of I/O<strong>com</strong>paris<strong>on</strong> errors(n<strong>on</strong>-localisable)Output <strong>com</strong>paris<strong>on</strong>single CP -single I/O (1oo1D)redundant CP -single I/O (1oo2D)redundant CP -redundant I/O (1oo2D)An output <strong>com</strong>paris<strong>on</strong> error is indicated by asystem flag. The fault resp<strong>on</strong>se “Systemshutdown, process group shutdown or alarm” shallbe programmed.SIL2: IF the process is c<strong>on</strong>tinuously m<strong>on</strong>itored by anoperatorAND the process safety time is sufficiently l<strong>on</strong>g toinsure manual shutdownAND the operator has sufficient means to m<strong>on</strong>itor andshutdown the process independent of the FSCsystemAND the fault is annunciated by fail-safe meansmanual reacti<strong>on</strong> and shutdown is permissible.SIL3: System shutdownSystem resp<strong>on</strong>sein the event offailure of fail-safeoutput modules(localisable fault)Depending <strong>on</strong> thelocality of the fault, thesystem resp<strong>on</strong>ds asfollows: Shutdown of outputsignal or Group shutdown or System shutdownDepending <strong>on</strong> thelocality of the fault, thesystem resp<strong>on</strong>ds asfollows: Shutdown of outputsignal of the channelc<strong>on</strong>cerned or Group shutdown ofthe channelc<strong>on</strong>cerned System shutdownDepending <strong>on</strong> thelocality of the fault, thesystem resp<strong>on</strong>ds asfollows: Shutdown of outputsignal of the channelc<strong>on</strong>cerned or Group shutdown ofthe channelc<strong>on</strong>cerned or Shutdown of theaffected central partSIL 3:C<strong>on</strong>tinued operati<strong>on</strong> fora period of time definedby the manufacturersPFD calculati<strong>on</strong> for aspecific system.(Note 4)Process groupshutdown or systemshutdown shall beprogrammed.Process groupshutdown or systemshutdown shall beprogrammed.Process groupshutdown or systemshutdown shall beprogrammed.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 16 of 33


SystemSystem resp<strong>on</strong>sein the event offailure of fail-safeinput modules(localisable faults)single CP -single I/O (1oo1D)Defective digital inputsare read as “0 signal”and in the case ofanalogue inputs, thec<strong>on</strong>figured minimumlimit is adopted."System shutdown,process group shutdownor alarm” shall beprogrammed.redundant CP -single I/O (1oo2D)Defective digital inputsare read as “0 signal”and in the case ofanalogue inputs, thec<strong>on</strong>figured minimumlimit is adopted.The fault resp<strong>on</strong>se"System shutdown,process group shutdownor alarm shall beprogrammedOR if the process isc<strong>on</strong>tinuouslym<strong>on</strong>itored by anoperatorAND the process safetytime is sufficientlyl<strong>on</strong>g to insure manualshutdownAND the operator hassufficient means tom<strong>on</strong>itor and shutdownthe processindependent of theFSC systemAND the fault isannunciated by failsafemeansmanual reacti<strong>on</strong> andshutdown is permissible.redundant CP -redundant I/O (1oo2D)The input signalsrecognised as defectiveare overwritten by thecorrect input signalsfrom the other channeland an error message isgenerated.The fault resp<strong>on</strong>se"Process groupshutdown or alarm” withc<strong>on</strong>tinued operati<strong>on</strong> fora period of time definedby the manufacturersPFD calculati<strong>on</strong> for aspecific system (Note 4)or "System shutdown"shall be programmed.Table 5: Central processing unit 10002/1/2 and 10012/1/2 (single processor)Note 4: Faults in redundant central parts which are detected and localised by the self-tests resultin single-central part operati<strong>on</strong> for a limited time period. The mode of operati<strong>on</strong>; single orredundant does not influence the coverage of the self-tests. The self-test interval is notextended for single-central part operati<strong>on</strong>. The self-test interval shall be less than thefault tolerance period of the process (PST).The fail-to-danger-rate of an applicati<strong>on</strong> including sensors and positi<strong>on</strong>ers at thec<strong>on</strong>troller’s ascertained MTBF figures and fault coverage rates are not significantlyincreased by single-channel operati<strong>on</strong> for a limited period. This period has to be definedby the manufacturers PFD calculati<strong>on</strong> for a specific systemTÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 17 of 33


The calculated maximum durati<strong>on</strong> for single-central part operati<strong>on</strong> depends <strong>on</strong> thespecific process c<strong>on</strong>cerned and must be specified individually for each applicati<strong>on</strong>. Onthe FSC system, this is specified by means of the system parameter "Interval timebetween faults".Note 5: SIL 1- 2: All faults which are <strong>on</strong>ly detected by <strong>com</strong>paring the internal system statuses ofthe two central parts and can not be localised result in a system alarmSIL 3: For central parts and output failures all faults which are <strong>on</strong>ly detected by<strong>com</strong>paring the internal system statuses of the two central parts and cannot be localisedresult in immediate shutdown of the system.Note 6: Multiple VBD Bus systems may be used for expansi<strong>on</strong> and I/O segregati<strong>on</strong>.2.3 Rec<strong>on</strong>figurati<strong>on</strong>The rec<strong>on</strong>figurati<strong>on</strong> opti<strong>on</strong>s possible and permissible depend <strong>on</strong> the safety classificati<strong>on</strong>applicable in each case and the system c<strong>on</strong>figurati<strong>on</strong>.In the event of faults <strong>on</strong> a safety-related input module, the input signal c<strong>on</strong>cerned is masked out(input signal set to zero, error flag set). In the event of faults <strong>on</strong> a safety-related output module, asub-process shutdown is performed if a sub-process has been c<strong>on</strong>figured to which the outputc<strong>on</strong>cerned bel<strong>on</strong>gs.The following table illustrates the relati<strong>on</strong>ship between the defined system c<strong>on</strong>figurati<strong>on</strong> and thepermissible rec<strong>on</strong>figurati<strong>on</strong> in the event of faults, which are not covered by the above faultresp<strong>on</strong>ses to peripheral faults. In particular, this includes central part faults and faults <strong>on</strong> thevertical and horiz<strong>on</strong>tal busses as well as faults <strong>on</strong> safety-related output modules if no subprocesseshave been c<strong>on</strong>figured.System C<strong>on</strong>figurati<strong>on</strong> Rec<strong>on</strong>figurati<strong>on</strong> Acti<strong>on</strong> After Eliminati<strong>on</strong> ofFaultsingle CP -single I/Oredundant CP -single I/Oredundant CP –redundant I/OSystem shutdownsingle CP - single I/O in the eventof faults <strong>on</strong> the central part.System shutdown or process groupshutdown in the event of faults <strong>on</strong> asafety-related output modulesingle CP -single I/ORestart after clearance fromthe operatorredundant CP -single I/ORestart after clearance fromthe operatorredundant CP -redundant I/ORe-activati<strong>on</strong> of subsystems after repair is possible while the system is running. In such cases,the restarted central part copies the data from the running system. The operator should treat allerror messages <strong>on</strong> start-up with particular cauti<strong>on</strong>.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 18 of 33


2.4 Mixed C<strong>on</strong>figurati<strong>on</strong>sIn order to provide greater capability of process-specific risk analysis and allocati<strong>on</strong> of processsignals to specific Safety Integrity Level, the FSC system offers the facility of mixed c<strong>on</strong>figurati<strong>on</strong>.The mixed c<strong>on</strong>figurati<strong>on</strong> "redundant CP - redundant I/O" / "redundant CP - single I/O)" allowprocessing signals of the Safety Integrity Level up to and including SIL 3.2.5 Possible Wiring Alternatives for Safety Integrity Level SIL 1 to SIL 32.5.1 InputsFor SIL 3 with redundant inputs, the input modules of both channels shall be used. Safety-relatedprocess variables shall be read from both busses.If fail-safe sensors are used for SIL 3 with single I/O, <strong>on</strong>e c<strong>on</strong>troller input for each safety-relatedprocess signal is sufficient. Programming and c<strong>on</strong>necti<strong>on</strong> of inputs for n<strong>on</strong> fail-safe sensors isexplained in detail in the Appendix C "Safety-Related Inputs with N<strong>on</strong>-Fail-Safe Sensors" of thecurrent FSC Software Manual.2.5.2 OutputsThe shutdown circuits in safety-related applicati<strong>on</strong>s shall always take the form of dualindependent circuits. In single I/O c<strong>on</strong>figurati<strong>on</strong>s up to and including SIL 3 this is provided byc<strong>on</strong>necti<strong>on</strong> of the output signal in series with the integrated sec<strong>on</strong>dary means of deenergizati<strong>on</strong>(group shutdown or total shutdown via watchdog) <strong>on</strong> the safety related output modules.In order to increase availability, in the system c<strong>on</strong>figurati<strong>on</strong> "redundant CP - redundant I/O", theoutputs of both channels are c<strong>on</strong>nected in parallel.In accordance with the applicati<strong>on</strong>-specific standards, it is assumed that for SIL 3 applicati<strong>on</strong>s,redundant actuators will normally be used, each of which is capable of bringing the process to asafe c<strong>on</strong>diti<strong>on</strong>.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 19 of 33


2.6 Communicati<strong>on</strong>The certified versi<strong>on</strong> of the operating system supports the following <strong>com</strong>municati<strong>on</strong> protocols:Data Transmissi<strong>on</strong> ProtocolFSC protocol for <strong>com</strong>municati<strong>on</strong> between two redundant central parts(up to SIL 3)FSC protocol for <strong>com</strong>municati<strong>on</strong> (multi-drop and point to point)between FSC systems (up to SIL 3)Modified RKE3964R protocol for <strong>com</strong>municati<strong>on</strong> (point to point) viapublic tele<strong>com</strong>municati<strong>on</strong> services (up to SIL 2) with extra measuresfor data integrity in the applicati<strong>on</strong> program via the FLD modules:MASTER_1, FIRST ISSUE, 07-26-1998SLAVE_62, FIRST ISSUE, 07-26-1998Communicati<strong>on</strong> via standard RKE3964R protocolCommunicati<strong>on</strong> with FSC NavigatorTransmissi<strong>on</strong> of data from and to peripheral systems (printer, processc<strong>on</strong>trol system, etc.)Communicati<strong>on</strong> via Modbus (RTU)Communicati<strong>on</strong> via Universal C<strong>on</strong>trol Network (UCN) with theHONEYWELL Total Plant Soluti<strong>on</strong> SystemCommunicati<strong>on</strong> via Ethernet with the HONEYWELL Experi<strong>on</strong> PKSsystem and Plantscape systemCommunicati<strong>on</strong> via PBUS with the ABB Automati<strong>on</strong> C<strong>on</strong>tr<strong>on</strong>ic E/Sprocess c<strong>on</strong>trol systemTransmissi<strong>on</strong> of Safety-Related Data Permissible?YesYesYesNoNoNoNoNoNoNoTable 6: Supported <strong>com</strong>municati<strong>on</strong> protocols2.6.1 Safety-Related Communicati<strong>on</strong> (FSC Protocol)The FSC system permits distributed c<strong>on</strong>figurati<strong>on</strong> of safety-related systems. In such cases, twobasically different <strong>com</strong>municati<strong>on</strong>s structures between the individual FSC systems can bec<strong>on</strong>structed: point to point links multi-drop linksBoth <strong>com</strong>municati<strong>on</strong>s structures can be used within the same system c<strong>on</strong>figurati<strong>on</strong>. To assist<strong>com</strong>municati<strong>on</strong> in such a network, <strong>on</strong>e system can be c<strong>on</strong>figured as a <strong>com</strong>municati<strong>on</strong>s server.The <strong>com</strong>plete <strong>com</strong>municati<strong>on</strong>s route including n<strong>on</strong>-safety-related transmissi<strong>on</strong> <strong>com</strong>p<strong>on</strong>ents suchas modems or fibre-optic cable links are covered by the safety procedures used.The safety-related data (marker bytes and register bytes) to be transmitted between the FSCsystems shall be identified as such during the parameterisati<strong>on</strong> process.The transmissi<strong>on</strong> times inherent in <strong>com</strong>municati<strong>on</strong> have the effect of lengthening the faultresp<strong>on</strong>se times of the relevant FSC systems. The increased fault resp<strong>on</strong>se time must be takeninto account and shall not exceed the process safety time of the applicati<strong>on</strong> c<strong>on</strong>cerned.Additi<strong>on</strong>al important informati<strong>on</strong> <strong>on</strong> FSC <strong>com</strong>municati<strong>on</strong> is given in the FSC Safety Manual.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 20 of 33


2.6.2 Safety-Related Communicati<strong>on</strong> (RKE 3964R Protocol)To establish <strong>com</strong>municati<strong>on</strong> via public tele<strong>com</strong>municati<strong>on</strong> services the modified RKE 3964Rprotocol together with extra measures for data integrity in the applicati<strong>on</strong> program can be used toexchange safety related data up to SIL 2.The extra measures must be programmed via the FSC logic functi<strong>on</strong>s and must fulfil followingrequirements: Timing integrity Address integrity Data integrity Wr<strong>on</strong>g sequence of telegramsUnlike the regular FSC protocol, these requirements are not implicitly covered with the standardRKE 3964R <strong>com</strong>municati<strong>on</strong> protocol, but must be programmed via the FSC logic functi<strong>on</strong>srealised with the modules MASTER_1 and SLAVE_62.The RKE protocol is a Point to Point protocol, and cannot be used for multi-drop <strong>com</strong>municati<strong>on</strong>s.The <strong>com</strong>plete <strong>com</strong>municati<strong>on</strong>s route including n<strong>on</strong>-safety-related transmissi<strong>on</strong> <strong>com</strong>p<strong>on</strong>ents suchas modems or fiber-optic cable links are covered by the safety procedures used.The safety-related data (marker bytes and register bytes) to be transmitted between the FSCsystems shall be identified as such during the parameterisati<strong>on</strong> process.The transmissi<strong>on</strong> times inherent in <strong>com</strong>municati<strong>on</strong> have the effect of lengthening the faultresp<strong>on</strong>se times of the relevant FSC systems. The increased fault resp<strong>on</strong>se time must be takeninto account and shall not exceed the process safety time of the applicati<strong>on</strong> c<strong>on</strong>cerned.Additi<strong>on</strong>al important informati<strong>on</strong> <strong>on</strong> RKE 3964R <strong>com</strong>municati<strong>on</strong> is given in the FSC SafetyManual.Note: If safety relevant <strong>com</strong>municati<strong>on</strong> is used the FSC-FSC protocol is preferred because allsafety checks are implemented in the system software.2.6.3 N<strong>on</strong>-Safety-Related Communicati<strong>on</strong>Use of the other transmissi<strong>on</strong> protocols provided by the FSC system - in particular the UniversalC<strong>on</strong>trol Network (UCN) to the H<strong>on</strong>eywell TotalPlant Soluti<strong>on</strong> System, the Ethernet protocol to theH<strong>on</strong>eywell Experi<strong>on</strong> PKS system and Plantscape system and the PBUS to the ABB Automati<strong>on</strong>C<strong>on</strong>tr<strong>on</strong>ic E/S process c<strong>on</strong>trol system - will not impair the safety-related performance of the FSCsystem or an FSC network, assuming that parameterisati<strong>on</strong> and applicati<strong>on</strong> programming havebeen correctly performed.The data sent and received by the n<strong>on</strong>-safety-related protocols shall normally be c<strong>on</strong>sidered asnot relevant to safety and shall be processed <strong>on</strong> that basis. The data exchange between FSCsystem and the menti<strong>on</strong>ed process c<strong>on</strong>trol systems can be c<strong>on</strong>figured to be: read <strong>on</strong>ly read and write(write <strong>on</strong>ly for n<strong>on</strong>-safety related variables in predefined memory areas)TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 21 of 33


2.6.4 Access to the FSC safety system by the FSC NavigatorDuring active operati<strong>on</strong> of the safety functi<strong>on</strong>s, the following modes of access to the FSC safetysystem by the PC operated applicati<strong>on</strong> development package „FSC Navigator“ are permitted:Read access: Reading of process statuses and FSC safety system statuses Diagnostic status of the FSC safety systemRead access by maintenance functi<strong>on</strong>s of the FSC Navigator „On-line rebuild“ of the FSC database <strong>on</strong> the FSC Navigator Reading back and checking the running applicati<strong>on</strong> programLimited Write access is also permitted for the following functi<strong>on</strong>s subject to clearance from theoperator. The resp<strong>on</strong>sibility for both functi<strong>on</strong>s lies with the operator. Forcing of "enabled" FSC variables.Forcing may <strong>on</strong>ly be authorised by way of a key-operated switch. Checking of whichsignals may be forced can be performed with the aid of a printout of the FSC variables. "Maintenance Override"Use of the “maintenance override” functi<strong>on</strong> must <strong>com</strong>ply with the requirements set out inthe current versi<strong>on</strong> of the document “Maintenance Override” published by TÜV SÜD andTÜV Rheinland.2.7 Compiling the Applicati<strong>on</strong> ProgramThe planning, programming and <strong>com</strong>piling of the applicati<strong>on</strong> program is carried out with the aid ofthe “FSC Navigator“. Since the hardware envir<strong>on</strong>ment of the FSC user stati<strong>on</strong> must be viewed asn<strong>on</strong>-safety-related, additi<strong>on</strong>al facilities have been implemented in the FSC programming systemin order to enable straightforward checking of correct <strong>com</strong>pilati<strong>on</strong> of the applicati<strong>on</strong> for the user.The functi<strong>on</strong>s referred to below are described in detail in the FSC Safety Manual.Compilati<strong>on</strong> of the applicati<strong>on</strong> is checked by an independent and diversely developed de<strong>com</strong>pilerand <strong>com</strong>parator (“Verify FSC Applicati<strong>on</strong> Software“ functi<strong>on</strong>). The project engineer shall perform ac<strong>on</strong>sistency check of the messages of that functi<strong>on</strong> <strong>on</strong> site and the CRC signature of theapplicati<strong>on</strong> software shall be <strong>com</strong>pared with the CRC signature of the applicati<strong>on</strong> work files.The functi<strong>on</strong> “Verify FSC Applicati<strong>on</strong> Software“ can also be employed as a revisi<strong>on</strong> <strong>com</strong>parator. Insuch situati<strong>on</strong>s, the modified applicati<strong>on</strong> is <strong>com</strong>pared with the original applicati<strong>on</strong>. Based <strong>on</strong> theexpectati<strong>on</strong> that all modificati<strong>on</strong>s must appear in the log file, it can be dem<strong>on</strong>strated that allmodificati<strong>on</strong>s have been correctly incorporated in the new applicati<strong>on</strong>.2.8 FSC safety checkerThe FSC safety checker is used to verify the safety c<strong>on</strong>sistency of any engineered FSCapplicati<strong>on</strong> created with the FSC Navigator software.The principle of the FSC safety checker is, that any output which is used for safety criticalapplicati<strong>on</strong>s (e.g. for shutdown purposes) should be set to safety related, and the path (inputs,logic) which results in this output should be safety related as well. Any inc<strong>on</strong>sistency with this rulewill be reported by the safety checker.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 22 of 33


2.9 Modifying the Applicati<strong>on</strong> Program during Operati<strong>on</strong>In the case of the redundant systems "redundant CP - single I/O", "redundant CP - redundant I/O"and mixed c<strong>on</strong>figurati<strong>on</strong> "redundant CP - redundant I/O" / "redundant CP - single I/O",applicati<strong>on</strong>s allow modificati<strong>on</strong>s to the applicati<strong>on</strong> software to be carried out during activeoperati<strong>on</strong>. A detailed descripti<strong>on</strong> of the procedure involved is given in the Appendix D "On-LineModificati<strong>on</strong>" in the FSC Software Manual.2.10 Fire and Gas applicati<strong>on</strong>sThe FSC system can be used for Fire & Gas applicati<strong>on</strong>s. The FSC Safety Manual (FS90-710),Chapter 9 “Fire and Gas Applicati<strong>on</strong> Example” and the special Fire and Gas Applicati<strong>on</strong> Manual(PM.MAN.8160) describe basic F&G applicati<strong>on</strong>s that are designed according to the requirementsof EN-54 part 2.A wide range of fire and gas field devices can be c<strong>on</strong>nected to the special fail-safe FTA's, FTA-T-18 or FC-TSGAS-1624 (analog gas and flame detectors) and FTA-T-19 or FC-TSFIRE-1624(c<strong>on</strong>venti<strong>on</strong>al fire detectors). The c<strong>on</strong>necting and signal handling details for these supported thirdparty devices are detailed in the Fire and Gas Field Devices Interface Manual (PM.MAN.8163).2.11 Machinery Safety applicati<strong>on</strong>sThe FSC system can be used for Machinery Safety applicati<strong>on</strong>s. The FSC Machine Safetymanual (PM.MAN.8172) describes basic machinery safety functi<strong>on</strong>s.The c<strong>on</strong>necting and signal handling details for these supported soluti<strong>on</strong>s are specified in the FSCMachine Safety Manual.2.12 Release identificati<strong>on</strong>This report covers the FSC Versi<strong>on</strong> 710.x where x indicates the actual (maintenance) release. Forthe release 710.2 the following safety related software <strong>com</strong>p<strong>on</strong>ents shall be used:- Central Processing Units, System software versi<strong>on</strong>: 71.02- Communicati<strong>on</strong> Modules, System software versi<strong>on</strong> (safety related): 71.02- Verify Applicati<strong>on</strong>: 48.1.0.0Details see release letter R710.2.All other software parts (not safety related) must have a versi<strong>on</strong>-number equal/greater than44.2.0.0 (FSC Navigator box) or equal/greater than 10.04 (M<strong>on</strong>itor System/FSC System/Versi<strong>on</strong>s)and can be modified by HSMS without new certificati<strong>on</strong> by TÜV SÜD Rail GmbH.The hardware modules are listed in secti<strong>on</strong> 2.1.3 and 2.1.4.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 23 of 33


3 Certificati<strong>on</strong> Requirements3.1 Basis of Certificati<strong>on</strong>The certificati<strong>on</strong> of the FSC Versi<strong>on</strong> 710.x will be according to the regulati<strong>on</strong>s and standardslisted in clause 3.3 of this document. This will certify the successful <strong>com</strong>pleti<strong>on</strong> of the followingtest segments:I. Functi<strong>on</strong>al safety Analysis of the system structure (FMEA system) Analysis of the hardware (FMEA <strong>com</strong>p<strong>on</strong>ent, quantitative analysis) Analysis of the software Fault simulati<strong>on</strong>s and software tests Test of the fault preventi<strong>on</strong> measures Functi<strong>on</strong>al testII. Electrical safetyIII. Susceptibility to envir<strong>on</strong>mental errors Climate and temperature Mechanical effectsIV. Electromagnetic <strong>com</strong>patibilityV. Safety informati<strong>on</strong> in the product documentati<strong>on</strong> (safety manual, operating instructi<strong>on</strong>s)VI. Product-related Quality Management in manufacturing and product care.Certificati<strong>on</strong> is dependent <strong>on</strong> successful <strong>com</strong>pleti<strong>on</strong> of all above listed test segments. The testingfollows the basic certificati<strong>on</strong> scheme for Safety Comp<strong>on</strong>ents of TÜV SÜD Rail GmbH.3.2 Certificati<strong>on</strong> Documentati<strong>on</strong>[1] Technical <str<strong>on</strong>g>Report</str<strong>on</strong>g> of Modificati<strong>on</strong>sZ10 09 04 20160 010Fail-Safe C<strong>on</strong>troller System Family, FSC Versi<strong>on</strong> 710.x<str<strong>on</strong>g>Report</str<strong>on</strong>g> No.: HH84600T, Versi<strong>on</strong> 1.0, dated 2012-10-17 related toTechnical <str<strong>on</strong>g>Report</str<strong>on</strong>g>: HH80661T[2] Technical <str<strong>on</strong>g>Report</str<strong>on</strong>g>Fail-Safe C<strong>on</strong>troller System Family, FSC Versi<strong>on</strong> 710.x<str<strong>on</strong>g>Report</str<strong>on</strong>g> No HH84624T, Versi<strong>on</strong> 1.0 of 5. February 2013[3] <str<strong>on</strong>g>Report</str<strong>on</strong>g> of the type approval of the Safety Manager R150.1<str<strong>on</strong>g>Report</str<strong>on</strong>g>-No.: 968/EZ 195.18/12 of 13. August 2012Certificati<strong>on</strong> report <strong>on</strong> the most recently tested versi<strong>on</strong>:[4] <str<strong>on</strong>g>Report</str<strong>on</strong>g> to the CertificateFSC Fail-Safe C<strong>on</strong>troller System FamilyVersi<strong>on</strong> 710.x<str<strong>on</strong>g>Report</str<strong>on</strong>g> no. SH99495C Revisi<strong>on</strong> 7.10 of 14. March 2011TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 24 of 33


Based <strong>on</strong> the specified purpose of use of the FSC Versi<strong>on</strong> 710.x in safety critical processapplicati<strong>on</strong>s, the certificati<strong>on</strong> is based <strong>on</strong> the following set of standards. The issuance of the<strong>certificate</strong> states <strong>com</strong>pliance with these references unless specifically noted otherwise.3.3 Functi<strong>on</strong>al SafetyThe testing for functi<strong>on</strong>al safety is to be performed using the following standards and guidelines:EN 61508-1:2001 (SIL 1-3)EN 61508-2:2001 (SIL 1-3)EN 61508-3:2001 (SIL 1-3)EN 61508-4:2001 (SIL 1-3)IEC 61511-1:2003 (SIL 1-3)IEC 61511-2:2004 (SIL 1-3)IEC 61511-3:2004 (SIL 1-3)Functi<strong>on</strong>al safety of electrical/electr<strong>on</strong>ic/programmable electr<strong>on</strong>icsafety-related systemsFuncti<strong>on</strong>al safety –Safety instrumented systems for the process industry sectorTÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 25 of 33


4 Results4.1 Functi<strong>on</strong>al SafetyThe tests performed and quality assurance measures implemented by the manufacturer haveshown that the FSC Versi<strong>on</strong> 710.x <strong>com</strong>plies with the testing criteria specified in clause 3 subjectto the c<strong>on</strong>diti<strong>on</strong>s defined in clause 5 and its subsecti<strong>on</strong>s, and is suitable for safety-related use inapplicati<strong>on</strong>s up to SIL 1-3 in accordance with EN 61508 and IEC 61511 and can be used e.g. inapplicati<strong>on</strong>s as Emergency Shut Down (ESD), Fire & Gas detecti<strong>on</strong> and Burner ManagementSystems.4.1.1 Fault Reacti<strong>on</strong> and TimingFault detecti<strong>on</strong> in the FSC Versi<strong>on</strong> 710.x is assured by means of following basic techniques:- self test at power up and during operati<strong>on</strong>- two channel c<strong>on</strong>trol logic with cross check- redundancy- dynamic signals- de - energizing in case of over – and under-voltage- de - energizing by watch dog m<strong>on</strong>itoring4.1.2 Evaluati<strong>on</strong> of fault preventi<strong>on</strong> measuresFor the avoidance of failures the following techniques and measures were used: Project management Documentati<strong>on</strong> Structured specificati<strong>on</strong> Inspecti<strong>on</strong> of the specificati<strong>on</strong> or walk-through of the specificati<strong>on</strong> Observance of relevant guidelines and standards Structured design Modularizati<strong>on</strong> Use of well tried <strong>com</strong>p<strong>on</strong>ents Inspecti<strong>on</strong> of the hardware Functi<strong>on</strong>al testing (also under envir<strong>on</strong>mental c<strong>on</strong>diti<strong>on</strong>s) Operati<strong>on</strong>al and maintenance instructi<strong>on</strong>s User- and maintenance friendlinessThe individual measures for the avoidance of failures provide the required degree of effectivenessand are specified in the relevant documents4.1.3 Analysis of the hardware safety integrity and hardware fault simulati<strong>on</strong>s (FIT)The Failure Mode Effect and Diagnostic Analysis (FMEDA) showed that the occurrence of asingle fault do not lead to loss of the safe functi<strong>on</strong>ing. The individual architectural c<strong>on</strong>strains aresufficient and their corresp<strong>on</strong>ding degree of fault detecti<strong>on</strong> provide the required degree ofeffectiveness.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 26 of 33


Resp<strong>on</strong>se Times:The resp<strong>on</strong>se time to external requests applied directly to the FSC system is no more than twicethe cycle time of the automati<strong>on</strong> system.In the case of single-channel system c<strong>on</strong>figurati<strong>on</strong>, individual faults capable of bringing about adangerous operating c<strong>on</strong>diti<strong>on</strong> are detected within the projected test cycle time (c<strong>on</strong>figuredprocess safety time) by the self-test and external test facilities. In the case of redundant systemc<strong>on</strong>figurati<strong>on</strong>s, additi<strong>on</strong>al to the selftests, individual faults are detected within the period of twocycles of the automati<strong>on</strong> system by <strong>com</strong>paring the two channels.In the case of distributed safety-related system c<strong>on</strong>figurati<strong>on</strong>s, additi<strong>on</strong>al fault resp<strong>on</strong>se timesmust be taken into c<strong>on</strong>siderati<strong>on</strong> (see FSC Safety Manual, chapter 5.4, entitled "FSC Networks").Resp<strong>on</strong>se of System to Faults:The resp<strong>on</strong>se of the FSC system to detected faults can be broadly determined by means of theapplicati<strong>on</strong> program. The resp<strong>on</strong>sibility for programming the system’s resp<strong>on</strong>se to faults lies withthe applicati<strong>on</strong> program developer. The standard system resp<strong>on</strong>ses or system messages aredetailed in the FSC Safety Manual in the chapter 6, “FSC System Fault Detecti<strong>on</strong> and Resp<strong>on</strong>se".Individual faults which can be definitely attributed to a particular central part by the highly effectiveself-tests result in rec<strong>on</strong>figurati<strong>on</strong> in the case of the FSC systems "redundant CP - single I/O" and"redundant CP - redundant I/O" due to the dual-channel c<strong>on</strong>figurati<strong>on</strong> and an error message issent to the applicati<strong>on</strong> program.In the case of operati<strong>on</strong> with c<strong>on</strong>tinuous supervisi<strong>on</strong>, i.e. if the operator can observe the processand can react quickly enough to bring the process to a safe c<strong>on</strong>diti<strong>on</strong>, a fail-safe alarm can beprogrammed instead of the system shutdown (see FSC Safety Manual, chapter 6 entitled "FSCSystem Fault Detecti<strong>on</strong> and Resp<strong>on</strong>se").4.1.4 Modificati<strong>on</strong>s to the Applicati<strong>on</strong> Program during Operati<strong>on</strong>On-line modificati<strong>on</strong>s presuppose applicati<strong>on</strong>s programs that have been subjected to particularlythorough testing beforehand, e.g. at simulators. In the case of such thoroughly tested applicati<strong>on</strong>programs, it is sufficient for all modificati<strong>on</strong>s made to be subjected to a full functi<strong>on</strong> test in order todem<strong>on</strong>strate correct functi<strong>on</strong>ing of the program. If n<strong>on</strong>-safety-related modificati<strong>on</strong>s are made, theyshall be subjected to suitable functi<strong>on</strong> tests in order to dem<strong>on</strong>strate absence of interacti<strong>on</strong>.In general, resp<strong>on</strong>sibility for m<strong>on</strong>itoring the process during the period of <strong>on</strong>-line modificati<strong>on</strong> liesentirely with the pers<strong>on</strong> resp<strong>on</strong>sible for the <strong>on</strong>-line modificati<strong>on</strong>. Since <strong>on</strong>-line modificati<strong>on</strong>s aregenerally associated with an increased level of risk, the approval of <strong>on</strong>-line modificati<strong>on</strong>s is at thediscreti<strong>on</strong> of the testing and inspecti<strong>on</strong> center resp<strong>on</strong>sible for approval of the system.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 27 of 33


4.2 Basic Safety and Electromagnetic Compatibility4.2.1 Electrical SafetyThe results about the electrical safety are documented by the <strong>certificate</strong>s and test reports of anaccredited test centre. No changes, <strong>com</strong>pare [4] for old references.4.2.2 Envir<strong>on</strong>nemental TestingThe envir<strong>on</strong>mental stress tests are documented by the <strong>certificate</strong>s of an accredited test centre.No changes, <strong>com</strong>pare [4] for old references.4.2.3 Electromagnetic CompatibilityThe tests of the electromagnetic <strong>com</strong>patibility are documented by the <strong>certificate</strong>s and test reportsof an accredited test centre. No changes, <strong>com</strong>pare [4] for old references.4.3 Product Specific Quality Assurance and C<strong>on</strong>trolThe software and hardware <strong>com</strong>p<strong>on</strong>ents developed and manufactured in course of the safetyevaluati<strong>on</strong> are governed by quality assurance and c<strong>on</strong>trol system.As part of the certificati<strong>on</strong> process TÜV SÜD also performs a procedure that is tailored to theassessed product in order to assess the c<strong>on</strong>sistency of product quality while accounting forproduct modificati<strong>on</strong>s and their identifiability (follow-up service).TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 28 of 33


5 Implementati<strong>on</strong> C<strong>on</strong>diti<strong>on</strong>s and Restricti<strong>on</strong>sUse of the Fail-Safe C<strong>on</strong>troller System Family FSC Versi<strong>on</strong> 710.x shall <strong>com</strong>ply with the currentversi<strong>on</strong> of the "Fail Safe C<strong>on</strong>trol (FSC) System Safety Manual" and the "Fail Safe C<strong>on</strong>trol (FSC)System Hardware Manual" and the "Fail Safe C<strong>on</strong>trol (FSC) Software Manual" and the “Fire andGas Applicati<strong>on</strong> Manual” and the “Fire and Gas Field Devices Interface Manual” and the “FailSafe C<strong>on</strong>trol Machine Safety Manual” of the <strong>com</strong>pany H<strong>on</strong>eywell Safety Management Systems.The following implementati<strong>on</strong> and installati<strong>on</strong> requirements have to be followed if the FSCVersi<strong>on</strong> 710.x is used in safety-related installati<strong>on</strong>s. The c<strong>on</strong>diti<strong>on</strong>s are arranged according to themajor stages of engineering a programmable electr<strong>on</strong>ic system for safety-related instrumentati<strong>on</strong>and protective equipment. The c<strong>on</strong>diti<strong>on</strong>s are further subdivided into n<strong>on</strong>-product-related c<strong>on</strong>diti<strong>on</strong>s which are not determined by the characteristics of the certifiedsystem but by the fundamental nature of safety-related programmable electr<strong>on</strong>ic systems, and product-related c<strong>on</strong>diti<strong>on</strong>s which arise from the characteristics of the certified system.5.1 Planning; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s5.1.1. The FSC Versi<strong>on</strong> 710.x can be used in applicati<strong>on</strong>s up to SIL 1-3 according to EN 61508and IEC61511.5.1.2. Only approved fail-safe hardware modules may be used for safety-related operati<strong>on</strong>. Theapproved hardware modules are listed in chapter 2.1.5.1.3. Checking of operating mode (RAM, FLASH or EPROM operati<strong>on</strong>), Safety Integrity Level,versi<strong>on</strong> number for the safety related software <strong>com</strong>p<strong>on</strong>ents defined in chapter 2.12"Release identificati<strong>on</strong>" and important system times such as test cycle time, sec<strong>on</strong>d faultoccurrence time, minimum and maximum program running time shall be performed bymeans of the "View FSC System and process status" program <strong>on</strong> the FSC Navigator(opti<strong>on</strong> parameters).In general, correct parameterisati<strong>on</strong> of system characteristics affecting safety should bechecked for all safety-related applicati<strong>on</strong>s (e.g. with the aid of the FSC diagnostic systemand fault simulati<strong>on</strong>).5.1.4. The safety system resp<strong>on</strong>se to faults and resp<strong>on</strong>se times shall be taken into c<strong>on</strong>siderati<strong>on</strong>and checked as detailed in chapter 4, “Results“, of this report.5.1.5. Safety-related resp<strong>on</strong>ses to faults which <strong>on</strong>ly result in an alarm are <strong>on</strong>ly permissible in thecase of operati<strong>on</strong> with permanent supervisi<strong>on</strong>.5.1.6. Except for fire detecti<strong>on</strong> and alarm applicati<strong>on</strong>s, the closed circuit principle shall be appliedto all external electrical safety circuits c<strong>on</strong>nected to the system. This means that for bothdigital and analog signals, the safe c<strong>on</strong>diti<strong>on</strong> is defined as the “zero c<strong>on</strong>diti<strong>on</strong>”.5.1.7. N<strong>on</strong>-fail-safe but n<strong>on</strong>-interacting modules may be used for processing n<strong>on</strong>-safety-relatedsignals but not for processing safety-related functi<strong>on</strong>s.5.1.8. Planning should include measures for provisi<strong>on</strong> of adequate overvoltage protecti<strong>on</strong> for the<strong>com</strong>plete system.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 29 of 33


5.1.9. The c<strong>on</strong>diti<strong>on</strong>s of use specified in the FSC Safety Manual shall be observed. Theguidelines, operating c<strong>on</strong>diti<strong>on</strong>s and the instructi<strong>on</strong>s for <strong>com</strong>missi<strong>on</strong>ing, described in theinstructi<strong>on</strong> manuals, have to be followed.5.1.10. Administrative measures shall be implemented by the operator in order to ensure that thebuffer batteries for preventing data loss from the volatile memory are checked andreplaced at regular intervals (see FSC Operati<strong>on</strong> and Maintenance Manual).5.1.11. The external supply of the output modules is <strong>on</strong>ly allowed with power supplies that fulfillIEC 61010 or IEC 60950.5.2 Planning; Product-Related C<strong>on</strong>diti<strong>on</strong>s5.2.1. In the case of the redundant system "redundant CP - redundant I/O", the total output loadshall not exceed the specified output load of a single output module because in the eventof a fault, the output modules are no l<strong>on</strong>ger redundant.5.2.2. When using the 4-channel digital output module FTA-T-08, the c<strong>on</strong>tact positi<strong>on</strong> of therelays shall be m<strong>on</strong>itored via safety-related input modules of the FSC Fail-Safe-C<strong>on</strong>troller.In applicati<strong>on</strong>s for SIL 3, two channels of the FTA-T-08 relay output module for each safetyrelevant output shall be used with the relay c<strong>on</strong>tacts in series.Because of the different requirements for relays in applicati<strong>on</strong> standards, it might benecessary to check the suitability of the relay (type of design, mechanical/electrical liveetc.) for the particular applicati<strong>on</strong>.5.2.3. The output signal of the undervoltage alarm circuit P366 of M24-12 and M24-20 shall <strong>on</strong>lybe processed by a safety-related input module of the FSC Fail-Safe C<strong>on</strong>troller.5.2.4. In an UCN <strong>com</strong>municati<strong>on</strong> link at least two grounded "UCN taps" shall be used, accordingto the installati<strong>on</strong> guide.5.2.5. If the FSC Fail-Safe C<strong>on</strong>troller is mounted in a cabinet separate from the ABB Automati<strong>on</strong>C<strong>on</strong>tr<strong>on</strong>ic E/S c<strong>on</strong>trol system cabinet then the PBUS c<strong>on</strong>necti<strong>on</strong> shall be via an opticallink.5.2.6. The output-voltage of the FTA-T-15 has to be checked by the applicati<strong>on</strong> program via themodule 10105/2/1.5.2.7. The relay <strong>on</strong> the FTA-T-19 may not be used for safety-related functi<strong>on</strong>s.5.3 Programming; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s5.3.1. The printed functi<strong>on</strong> block diagrams shall be <strong>com</strong>pared with the previously preparedfuncti<strong>on</strong> block diagrams.5.4 Programming; Product-Related C<strong>on</strong>diti<strong>on</strong>s5.4.1. The resp<strong>on</strong>se of the system to faults <strong>on</strong> the hardware modules shall be specified by theapplicati<strong>on</strong> program in accordance with the particular safety-related circumstances of thesystem. The default c<strong>on</strong>figured resp<strong>on</strong>se is an automatic safe acti<strong>on</strong>.5.4.2. In the event of a sub-process shutdown <strong>on</strong> the system "redundant CP - redundant I/O"; i.e.a fault <strong>on</strong> the fail safe output modules, a timer shall instigate rec<strong>on</strong>figurati<strong>on</strong> of the systemafter expiry of a sec<strong>on</strong>d-fault occurrence time defined according to the demands of theindividual applicati<strong>on</strong>.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 30 of 33


5.4.3. The use of safety-related Counter Functi<strong>on</strong>ality is suitable for processes in which thecounter signal is changing within the sec<strong>on</strong>d-fault occurrence time. The planning andprogramming of the counter functi<strong>on</strong>ality shall <strong>com</strong>ply with the manual „Fail Safe C<strong>on</strong>trol,Technical Note, FSC Safety-Related Counter Functi<strong>on</strong>ality“.5.5 Communicati<strong>on</strong>; Product-Related C<strong>on</strong>diti<strong>on</strong>s5.5.1. Safety-related <strong>com</strong>municati<strong>on</strong> (FSC protocol) is <strong>on</strong>ly permitted within the Fail-SafeC<strong>on</strong>troller System Family.5.5.2. For safety-related <strong>com</strong>municati<strong>on</strong>, the safe c<strong>on</strong>diti<strong>on</strong> for transmissi<strong>on</strong> data shall be “zero”.5.5.3. To establish safety related <strong>com</strong>municati<strong>on</strong> via public tele<strong>com</strong>municati<strong>on</strong> services themodified RKE 3964R protocol may be used also but extra measures for data integrity mustbe programmed via FSC logic functi<strong>on</strong>s and must fulfill the requirements according SIL 2(see also chapter 2.6.2). This is realised with the following modules which must be usedfor the safety relevant <strong>com</strong>municati<strong>on</strong>:- MASTER_1, FIRST ISSUE, 07-26-1998- SLAVE_62, FIRST ISSUE, 07-26-19985.6 Special Operating Modes; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s5.6.1. Modificati<strong>on</strong>s during active operati<strong>on</strong> (<strong>on</strong>-line modificati<strong>on</strong>s) are permissible <strong>on</strong>ly afterc<strong>on</strong>sultati<strong>on</strong> with the inspecti<strong>on</strong> and testing centre resp<strong>on</strong>sible for approval of theapplicati<strong>on</strong>.5.6.2. Resp<strong>on</strong>sibility for m<strong>on</strong>itoring the process while <strong>on</strong>-line modificati<strong>on</strong>s are being carried outis that of the pers<strong>on</strong> resp<strong>on</strong>sible for the <strong>on</strong>-line modificati<strong>on</strong>s. All system messagesreceived while carrying out <strong>on</strong>-line modificati<strong>on</strong>s are to be treated with the utmost cauti<strong>on</strong>.5.6.3. On-line modificati<strong>on</strong>s presuppose applicati<strong>on</strong>s programs that have been subjected toparticularly thorough testing beforehand, e.g. at simulators. In the case of such thoroughlytested applicati<strong>on</strong> programs, as part of the <strong>on</strong>-line modificati<strong>on</strong> process, at least allfuncti<strong>on</strong>s reported by the functi<strong>on</strong> “Verify FSC Applicati<strong>on</strong> Software“ of the FSC Navigatoras having been modified shall be subjected to a full functi<strong>on</strong> test.The operator shall <strong>com</strong>pare all changes reported during the process of <strong>on</strong>-linemodificati<strong>on</strong> with the modificati<strong>on</strong>s he/she has made and investigate any discrepancies(i.e. apparently unmodified applicati<strong>on</strong> sheet reported as having been modified) anddocument the causes.5.6.4. The use of "maintenance override" shall <strong>com</strong>ply with the current versi<strong>on</strong> of the document"Maintenance Override" published by TÜV SÜD and TÜV Rheinland.5.6.5. Forcing of signals shall <strong>on</strong>ly be possible allowed under the supervisi<strong>on</strong> of a key-operatedswitch and is the resp<strong>on</strong>sibility of the operator al<strong>on</strong>e. Checking of which signals may beforced can be performed with the aid of a printout of the FSC variables.5.6.6. If the user program is stored in RAM or Flash, inadvertent alterati<strong>on</strong> of the user programshall be prevented by means of password protecti<strong>on</strong>.5.7 Special Operating Modes; Product-Related C<strong>on</strong>diti<strong>on</strong>sN<strong>on</strong>eTÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 31 of 33


5.8 Fire Detecti<strong>on</strong> and Alarm Installati<strong>on</strong>s; N<strong>on</strong>-Product-Related C<strong>on</strong>diti<strong>on</strong>s5.8.1. The energy shall be provided by an un-interruptable power supply (UPS). The bridge-overdurati<strong>on</strong> and the alarm durati<strong>on</strong> will be determined by the applicati<strong>on</strong> and by the effectivenati<strong>on</strong>al requirements.5.8.2. The power supply of an alarm installati<strong>on</strong> following DIN VDE 0833 shall be independent ofthe supply of any other installati<strong>on</strong>.5.8.3. The installati<strong>on</strong> shall provide for an alarm horn of at least 60 dB and for a nuisance alarmof at least 50 dB.TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 32 of 33


6 Certificate NumberThis report specifies technical details and implementati<strong>on</strong> c<strong>on</strong>diti<strong>on</strong>s required for the applicati<strong>on</strong>of FSC Versi<strong>on</strong> 710.x to the <strong>certificate</strong>:Munich, 2013-02-05Z10 13 01 20160 012TÜV SÜD Rail GmbHGenerische SicherheitssystemeGuido Neumann(Technical Certifier)TÜV SÜD Rail GmbH 717506225Generic Safety Systems HH84623C_Rev1.0.docx / Rev. 1.0Barthstraße 16 • D-80339 Munich • GermanyAuthor: Martin BraunPh<strong>on</strong>e: +49 (89) 5190 -2899, Fax: -2933 05.02.2013E-Mail: martin.braun@tuev-sued.de Page 33 of 33

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