Product Information Note
Safety Manager
Process Solutions
Safety Manager combines Honeywell’s proven Quadruple
Honeywell’s Safety Manager, part of the Experion® Process Knowledge System
(PKS), enhances the safety, reliability and efficiency of critical processes.
Experion® PKS – The Knowledge to Make it Possible.
Modular Redundancy (QMR®) 2oo4D technology with extensive
process safety management expertise in integrating process
safety data, applications, system diagnostics and critical control
strategies.
Honeywell’s IEC 61511 and IEC 61508 SIL 3 TÜV certified
solution provides the optimal level of safety and process
integration while still maintaining functional safety separation as
mandated by those standards. Through Experion operational
integration, all systems are unified into one operationally
integrated architecture, providing a unique opportunity to improve
safety, process availability and efficiency.
Experion provides unprecedented connectivity through all levels
of process and business operations to optimize work processes,
improve routine maintenance efficiencies, enhance safety
management and release personnel from manual processes.
Benefits
Safe and Secure – Safety Manager is designed to be securely
integrated into customer systems and has passed very
rigorous security testing as defined by ISA Security
Compliance Institute (ISCI).
Safety Manager was the first safety system to achieve
Embedded Device Security Assurance (EDSA) certification.
ISCI developed this certification within the framework of the
ISA Industrial Automation and Control Systems security
standards (ISA 99). Because of the built in protection
mechanisms, the Experion Safety Manager is protected from
cyber attacks and disruption of service.
High Availability Architecture – Honeywell’s field-proven
QMR 2oo4D architecture provides the highest availability with
a safe architecture. Applying QMR technology allows
uninterrupted process operation in the event of any system
degradation or on-process modification without jeopardizing
the SIL 3 level. The optional Safety Manager A.R.T. (Advanced
Redundancy Technique) provides additional benefits for
locations where timely maintenance is not available.
Easy and Intuitive Engineering and Modifications – Safety
Builder, an intuitive and comprehensive configuration tool,
provides plant-wide management of safety-critical databases
and application programming for easy network design. TÜVapproved, menu-driven online modifications prevent errors
while maintaining and optimizing the safety application.
Defense-in-Depth – SafeNet and remote distributed Safety
Manager provide the ability to design defense-in-depth safety
strategies that maximize safety and security while minimizing
risk and scope-of-loss concerns.
Safety Networking - The networking capabilities of Safety
Manager are unsurpassed. Up to 1024 redundant nodes can
be included in one safety network, acting as one integrated
safety solution. The SIL 4 certified SafeNet communication
protocol guarantees fast and safe communication over any
media and distance. The remote management capabilities
support centralized management of all connected safety
systems.
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SafeNet Flexibility - SafeNet can run over any network, such
as a dedicated separated safety network as well as the
Honeywell Fault Tolerant Ethernet (FTE) network
infrastructure. SafeNet is the only SIL 4 certified
communication protocol available in process networks today.
Self-Learning – Replacing any module, including the safety
processor, is possible when the plant is in operation, and data
and programs are automatically copied from the running
processor. There is no manual loading required, which
simplifies handling and avoids problems. The total system will
continue to meet the stringent SIL 3 requirements.
High Performance – Safety Manager has been optimized to
manage large applications with over 1,000 I/O as well as highspeed applications with fast processing requirements of cycle
times well below 100 milliseconds.
Universal Safety I/O – Safety Manager Universal Safety I/O
enables maximum architectural flexibility and lowest cost of
Localized Safeguarding - With Universal Safety Logic Solver,
the safety application can be distributed into the field close to
the process unit while maintaining a transparent overview of
the overall safety application. The unique feature of this
Universal Safety IO module is the fact that besides being an IO
module to Safety Manager, it can execute the safety
application locally. Safeguarding the process even in the event
communications to the Safety Manager are interrupted.
Standardized Solutions - Universal Channel Technology
enables Universal Cabinet designs to be standardized,
significantly reducing engineering cost and schedule when
applied broadly across a project.
Advanced Experion Integration – Supports Safety Manager
integration in Experion, providing an integrated safety and
control solution. It enables, for example, transmitter data
sharing between the CEE (Control Execution Environment)
controllers and Safety Manager, via direct peer to peer
communication, to save installed and operational costs. Peer
to peer communication further allows for alarm suppression,
automatic bypassing and interlocks between shutdown and
control functions as well as “soft landing” in case of process
upset. It also provides easy operator access and full Console
Station support. As part of the “enter data only once”
philosophy, the Experion-related properties are configured
from the Safety Builder tool simplifying maintenance and
reducing total cost of ownership.
ownership when safety is required at distributed locations. It
has the unique feature that each channel can be configured
individually to a different I/O type. Every Universal Safety I/O
module has a capacity of 32 freely configurable channels,
enabling savings on both installation and operational costs. By
using soft-marshalling, the Universal Safety I/O module can be
mounted close to the process unit, eliminating the need for
marshalling panels, homerun cables and reducing or
eliminating field auxiliary rooms. This approach is ideally suited
to highly distributed applications such as oil and gas upstream
applications, and reduces cost while increasing availability and
efficiency. This reduces overall capital expenditure, as well as
maintenance costs.
Built on QMR Technology – Safety Manager is based on the
unique and field-proven QMR diagnostic-based technology
with 2oo4D architecture. QMR enhances system flexibility,
increases diagnostic messaging capabilities and improves
system fault tolerance for critical applications. It enables the
handling of multiple system faults within Experion Safety
Manager, matching the needs of critical control applications.
In addition, Safety Manager provides the basis for integrating
SIL-rated field sensors and valve actuators, ensuring that
safety functions are well established to protect complex and
hazardous processes. It integrates SIL 1-3 safety transmitters
(such as Honeywell ST3000 and STT250) or safety valve
positioners for improved safety and field asset management.
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Optimized field maintenance - Without the need for extra
infrastructure or engineering, HART devices are integrated
within Honeywell’s Field Device Manager. This provides all
required data for field asset management. To prevent
inadvertent device changes, the safety manager prevents FDM
from writing parameter changes unless the device safety lock
has been disabled from Safety Builder.
Compliance to Safety Standards
A major requirement for compliance with IEC 61511 and IEC
61508 is the availability of a change history of applications. With
Safety Builder, change history is efficiently tracked with the
Safety Audit Tracker through an automatically enabled audit trail.
Difficult procedures or extensive loggings are not required. The
Safety Audit Tracker, together with the automated embedded
Application Verification mechanism, is all that is required.
Safety Manager complies with the following international
standards:
For burner management: NFPA 85, 86, EN50156
For emergency shutdown and other critical applications:
IEC 61508, IEC61511, ISA S84.01, DIN V 19250, UL,
FM, ATEX
For fire and gas: EN54-2, NFPA 72, Lloyd’s Register
and offshore installations ABS
With all SIL 3 safety hardware and software compliance tools,
Safety Manager provides excellent protection for safety
applications across multiple industries throughout the entire life of
an installation. Safety Manager provides the basis for critical
control and safety unification, reducing risks and installed costs,
and improving safety while increasing uptime.
Optimized Engineering Environment
Safety Builder software improves engineering and design
efficiency. With simple drag and drop functionality, a complete
and complex network can be designed within minutes without
programming, saving valuable engineering and testing time. The
complete network design is available on a one-page view without
requiring additional documentation.
An integrated editor facilitates fast and effective application
design, allowing clear and distinct views of all logic with full
compliance to IEC 61131 standards. Logic inputs, outputs and
symbols are placed with drag and drop functionality from the
toolbar and are easily configurable.
Through the Safety Manager simulation mode any application
can be loaded and tested on a minimum size system, a tool that
facilitates easy application design and testing. The simulation
mode also allows execution of online modifications and testing of
all communication interfaces.
In absence of a Safety Manager system the Honeywell’s
UniSim® simulation environment for Safety Manager supports
offline simulation as well. It can help in the early implementation
phase of a project or as part of a plant-wide system simulation. It
supports step by step simulation, freezing the application and
building snapshots.
Optimal Process Availability
Applying QMR technology to Safety Manager delivers unlimited
runtime for single channel operation. This increases process
availability, allowing uninterrupted process operation in the event
of any system degradation. Without incurring any process
downtime, the system can be kept up to date with the latest
system software as well as application changes or additions
through a four-step online system modification procedure The onprocess modification to the application can be carried out
remotely without physical presence to the system.
I/O faults are detected and isolated on a per-channel basis and
immediately reported to the appropriate level. This minimizes the
time to repair and further increases system robustness.
Integrated Operation and Maintenance
Safety Manager unifies critical safety process data with process
control information, providing single-window access for operation
and maintenance. When connected to the Honeywell FTE
network through TÜV SIL 3 approved Universal Safety
Interfaces, multiple Safety Managers can be unified into one
safety system architecture.
Safety Manager integration delivers fast, safe and reliable data
exchange with Experion, enhancing operator and maintenance
performance. In addition, Safety Manager extends the system
proof test interval with inherent extensive system self-testing and
diagnostic capability, reducing operational and maintenance
costs. Integrated sequence of events (SOE) functionality for all
process and safety-related activities supports analysis at a
glance.
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Safeguards are built into Safety Manager to eliminate the
possibility of systematic failures caused by errors made during
the design, planning, construction, operation and
decommissioning of the system. A systematic failure in the
design of a common tool can result in an unsafe reaction of both
the safety and control systems.
Safety through Separation
Safety and control systems must be integrated to allow for
smooth and safe plant operation, while still maintaining a safe
separation where appropriate.
Secure Separated Databases - Within Honeywell’s unique
solution, separate databases store the safety and control
strategies, and separate software modules are available for
safety and control through dedicated tools such as Safety
Builder and Control Builder. Maintaining separate tools with
separate databases prevents unauthorized changes or
corruptions, decreases safety risks and prevents common cause
failures.
Managed and Protected Database Environment - A unique,
secure login scheme protects Safety Manager from off- and onprocess changes. This login scheme uses a dedicated
protection mechanism with several access levels for the
engineering application, loading of the application in the
controller and forcing points in Safety Manager. A user
expiration mechanism downgrades the access level after a
user-defined period of time elapses to protect the application
from accidental or unauthorized changes when Safety Builder is
unmanned over a specified period.
Dedicated Software and Hardware - Using dedicated and
specifically developed hardware and software in accordance
with the IEC61508 safety standard reduces the risk of a
common cause failure. Using dedicated hardware and software
for both safety and control protects the safety system from any
defects in control-related operations. In addition, the safety and
control strategies are developed by different groups using
dedicated methods.
Conversely, using the same hardware or software for both
safety and control increases the possibility of systematic
controller failures, including those that result from design
errors. A clear separation reduces the effort for testing and
designing safety systems.
Secure Environment - It is crucial that critical control and SIS
are protected from intentional or accidental cyber threats. In
general, functional security in combination with functional
safety is critical to assessing the overall integrity of a SIS.
Safety Manager architecture is secure by design and is
certified to the Embedded Device Security Assurance program
as defined by the ISA Security Compliance Institute.
Adherence to this standard provides assurance of safety,
security and robustness, meeting stringent industry best
practices and performance benchmarks.
In addition, Safety Manager is protected from outside threats
by an embedded certified hardware firewall. This firewall
isolates the safety application during runtime execution from
external devices so they can never jeopardize the safety or
availability of the application. With this firewall and the use of a
SIL 4 certified proprietary protocol between safety managers,
the data integrity between control and safety is protected and
guaranteed.
Safety Inside - Using dedicated firmware for safety and control
ensures that safety is embedded into the system—no
additional programming is needed to establish the required
safety level. Strategies with a common platform for safety and
control require that safety be built into the application. This
customized safety level is a manual process and requires
fundamental knowledge of the safety system to establish
safety functions without jeopardizing the integrity of the
application.
Honeywell’s integrated control and safety solution is driven by
the separation principle—hardware and software
diversification, integrated operator interface, integrated data
processing and analysis, and integrated alarm management.
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For More Information
To learn more about Honeywell’s Safety
manager, visit our website
www.honeywellprocess.com or contact
your Honeywell account manager.
Honeywell Process Solutions
Honeywell
1250 West Sam Houston Parkway South
Houston, TX 77042
Honeywell House, Arlington Business Park
Bracknell, Berkshire, England RG12 1EB UK
Shanghai City Centre, 100 Junyi Road
Shanghai, China 20051
www.honeywellprocess.com
PN-12-25-ENG
March 2013
© 2012 Honeywell International Inc.
Experion®, QMR® and UniSim® are registered trademarks of Honeywell
International Inc.
The operational integration provided with Experion and Safety
Manager allows plant personnel to have a seamless interface
to the process while maintaining safe separation. This allows
for a wide range of applications to be monitored plant-wide
from any operator console. A complete overview of all
information needed from the operator’s point of view is
available through Experion Station or Experion Console
Station. This communication architecture, supplied by
Honeywell, delivers a scalable solution, from small control and
safety networks to huge plant architectures with over 100,000
monitored I/O points. Interoperability of Safety Manager with
the SafeNet protocol extends the functionality of one Safety
Manager and allows for plant-wide implementation, binding the
separate functionalities into one safety application with
different protection layers.
Engineering Excellence
Honeywell’s Global Safety Discipline program enables consistent
project execution excellence across Honeywell engineering
locations. TÜV certified procedures and resources guarantee a
global and transparent safety project execution by using certified
standard builds, including templates, guidelines solution libraries,
checklists, methodologies and tools.
Safety Manager HMIWeb Solution Pack shapes and faceplates
provide all projects with a highly flexible and functional library,
enabling maximum advantage of the principles of safe and
effective operations as described by the Abnormal Situation
Management (ASM) Consortium.
Honeywell Safety Services
Honeywell’s offerings go beyond supplying hardware and
software, establishing a unique safety knowledge community
located in our expertise centers around the world in North
America, Europe, South Africa, Asia and Australia.
Over 200 certified safety engineers employed in these centers
offer a wide range of consulting, project and lifecycle support
services, including:
Safety system audits
Process hazard and risk assessment
SIL classification
IEC61508 and IEC61511 CFSE training
Safety requirement specification development
FEED studies with customers to jointly develop their
requirements
IEC61508, IEC61511 and ISA S84 compliant solutions
development
Safety Instrumented Systems implementation
Live, hot cutover implementation and execution of
revamp projects
Installation and commissioning
SIL verification
SIL validation
Periodic proof-testing
System maintenance
Solution Enhancement Support Program (SESP)
Parts management
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