Process Safety Solutions

Protecting People, the Environment, and Critical Control Assets

 Process Safety Solutions
Hazards and risks are an inevitable feature of any industrial application and process
safety is a major concern to anyone who works in the process industries. The
protection of personnel, processes, and the surrounding environment remains a
significant part of any automation strategy.

With over 50 years of safety expertise, Rockwell Automation® technology is utilized in

safety and critical control processes throughout the world. Our ICS Triplex® brand of
safety critical shutdown has been a recognized leader in process industries creating
maximum availability and reliability for a host of applications.

Rockwell Automation® technology has been utilized

in many critical control applications:
• Emergency shutdown
• Fire and gas
• Spill prevention
• HIPPS
• Burner management
• Compressor control
• Turbine control

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Safety First. Safety Last.
A Safety Instrumented System (SIS) is engineered to perform Our scalable offerings, in both size and redundancy, allow you
“specific control functions” to fail safe or maintain safe to select the system that best meets these requirements:
operation of a process when unacceptable or dangerous • SIL Capabilities
conditions could occur. • Fail Safe and Fault Tolerance
• Performance
Rockwell Automation can help you select a process safety • Size
system – whether standalone or integrated – based on • Connectivity
required Safety Integrity Level (SIL) and your project • Flexibility
requirements.

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 Rockwell Automation Process Safety Offerings
Rockwell Automation provides you with multiple choices for your
process safety applications allowing you to select the right-sized system
without extra costs.

AADvance System
The AADvance® solution is a truly distributed, scalable architecture which comprises
both a hardware controller and a software environment that allows you to specify the
level of safety integrity and availability you need throughout your plant. AADvance offers
a high level of flexibility from small quantity I/O to large systems; non-safety to SIL 3, and
fail-safe to multiple fault tolerant.

Integrated Control and Safety Comprehensive Programming Environment

• CIP™ (EtherNet/IP™) communications to Logix controllers • Supports all 5 IEC 61131 programming languages
• OPC Data Access (DA) & Alarm & Event (A&E) communications • Built in version control
• Modbus communications • T3 compliant online modifications and expansion
• Online programming changes
Scalable Architectures • Online debugging
• Distributed controller architecture • Offline simulation
• Flexible processor redundancy configurations • Single programming environment to manage multiple
• Flexible I/O fault tolerant configurations controllers for distributed safety applications
• Black channel communications

Feature Rich Hardware

• Comprehensive diagnostics
• Integrated HART communications (AI & AO)
• Channel isolation
• Electronically protected outputs
• Online replaceable

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Typical Applications* SIL Target Demand
Emergency Shutdown (ESD) 2&3 Low / High
Fire and Gas (F&G) 2 Low
High Integrity Pressure System (HIPPS) 3 Low
Burner Management Systems (BMS) 2 High
Subsea (BoP) 2 Low
* All safety applications are unique. We encourage you to speak with a Rockwell Automation Safety Consultant
to be certain the correct SIS system is selected for your application.

AADvance Multi-SIL Configurable Architecture

AADvance™ Workbench
Software Server

Ethernet based Safety Network

SIL1 - 2 Fail Safe SIL2 - 3 Fault Tolerant SIL3 Fault Tolerant SIL3 Triple Modular
Redundant Redundant

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 Trusted System
The Trusted® solution features a Triple Modular Redundant (TMR) controller. It is
designed to provide maximum safety and system availability. Trusted® uses control to
minimize system trips and provides high availability, fault tolerance and fail-safe features
as part of its intrinsic, safety-related functionality.

Trusted System
Trusted is designed to meet a wide range of safety requirements With combined Hardware Implemented Fault Tolerance (HIFT)
and maintain the highest integrity level, even in the presence of and TMR technology, Trusted can offer you the following
multiple system failures. key capabilities:
• A Safety Integrity Level of 3 (SIL3) and fault tolerant
The Trusted TMR design uses a majority voting process to • Stable, predictable operation
identify the source of a fault. Random hardware failures will cause • High capacity and high speed
one of three control ‘slices’ to react differently to the others. • Easy to use and maintain
This discrepancy will be captured and reported by the voting • High density I/O (up to 40 channels/module)
system. The Trusted TMR system will react immediately to
contain system faults, helping to ensure it meets your safety
integrity requirements.

The hardware voting technology has major

benefits including:
• High test coverage of potential faults
• Tolerance to multiple failures
• No restrictions on time-to-repair
• Accurate fault identification
• Reduced operating system size and complexity

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 Typical Applications* SIL Target Demand
Emergency Shutdown (ESD) 2&3 Low / High
Fire and Gas (F&G) 2 Low
Turbo Machinery Control (TMC) 2 High
Burner Management Systems (BMS) 2 High
High Integrity Pressure System (HIPPS) 3 Low
* All safety applications are unique. We encourage you to speak with a
Rockwell Automation Safety Consultant to be certain the correct
SIS system is selected for your application.

Trusted® Architecture
Workbench Software Server

Ethernet based Safety Network

SIL3 TMR SIL3 TMR

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 ControlLogix SIL2
The ControlLogix® SIL2 solution provides very high levels of availability for those SIL2
Basic Process Control System and/or Process Safety System applications that cannot
tolerate a system shutdown.

Reliability by Design
Sophisticated diagnostics and high levels of reliability are standard design
in ControlLogix programmable automation controllers, I/O modules, and
communication products. It is that same, standard design that readily
provides the reliability needed to achieve SIL 2 certification.

Standard Design Yields Exceptional Savings

The ability to use standard, off-the-shelf ControlLogix solutions in SIL 2
applications helps eliminate the need for additional training and ensures
that spare parts are readily available. That is why many major petroleum
customers use ControlLogix, saving more than 80% of the cost of
other solutions.

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Typical Applications* SIL Target Demand
Burner Management Systems (BMS) 2 High
Turbo Machinery Control (TMC) 2 High
Power Equipment 2 Low
* All safety applications are unique. We encourage you to speak with a Rockwell Automation Safety Consultant
to be certain the correct SIS system is selected for your application.

ControlLogix SIL2

Operator Visualization Engineering

Station Servers Workstation

EtherNet/IP Supervisory Network

EtherNet/IP Control Network

Redundant I/O Redundant I/O

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 OptiSIS Packaged Solutions
Compliant with ISA 84/IEC61511, the OptiSIS™ safety instrumented system is an ideal
solution for diverse SIS replacement/upgrade projects, utilizing an “off the shelf”
common solution. Featuring a standard logic solver capable of meeting SIL
requirements up to SIL 3, it is simpler, faster, and more cost-effective to deploy than
a custom-designed SIS solution.

Reduce Lead Times

The OptiSIS packaged solution helps reduce lead times
associated with customized safety solutions. The focus is
on configuring safety functions, rather than engineering
and safety manual compliance tasks.

• Configured from a Cause and Effect Matrix

(no programming)
• Rapid deployment to the field
• Quick installation, easy upgrades
• Reduced risk at installation (rapid verification)
• Connectivity to smart field devices and asset
management systems

Typical Applications* SIL Target Demand

Emergency Shutdown (ESD) 2&3 Low / High
Fire and Gas (F&G) 2 Low
High Integrity Pressure System (HIPPS) 3 Low
Burner Management Systems (BMS) 2 High
* All safety applications are unique. We encourage you to speak with a
Rockwell Automation Safety Consultant to be certain the correct
SIS system is selected for your application.

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Integrated Control and Safety System (ICSS)
Rockwell Automation can provide flexible and scalable process control and safety
solutions that easily allow implementation strategies to best meet your integrated
control and safety system needs.

AADvance, Trusted and ControlLogix SIL2 can be configured:

• As standalone SIS systems that can communicate to all major DCS and PLC (BPCS) vendors thru Modbus Serial,
Modbus TCP/IP, or EtherNet/IP.
• As standalone SIS systems that can be integrated into the PlantPAx distributed control system control strategy
• As part of an overall Integrated Control and Safety System (ICSS)

Operator PlantPAx Engineering Historian

Workstation Servers Workstation Server

AADvance
Workbench
Software Server

Ethernet Switch A (Information & Control Network)

Ethernet Switch B (Information & Control Network)

OPC Server
CIP

CIP

MB RTU
MB TCP

AADvance Trusted Redundant I/O ControlLogix

SNCP

Local Operator panel

SNCP

SNCP

SNCP
(PanelView +)

Ethernet Switch A (Safety Critical Network)

Ethernet Switch B (Safety Critical Network)

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A World of Process Safety Experience
Rockwell Automation has a global safety team of consultants ready to assist end users, integrators and OEMs Our aim? To provide your
organization with the solutions and services you need to maximize production throughout your automation lifecycle – from design and
installation through operation and migration.

We’ll help you achieve your functional safety targets for the entire process, while helping to maintain your productivity goals.
• Functional Safety Management Systems • Product Certification
• Hazard and Operability (HAZOP) Study • Quantified Risk Assessment (QRA)
• Safety Integrity Level (SIL) Targeting • Dispersion Modeling / Consequence Analysis
• SIL Assessment • General Reliability / Availability Studies

Delivering Value – and Confidence

When you work with Rockwell Automation, you engage a team Our expertise spans a wide range of industries and includes
focused on listening to you – and learning about your issues and complete solution delivery capabilities that complement and
objectives. Then, we apply our domain expertise, global enhance our product offerings. we will draw on our expertise and
execution ability and certified project management methodology partner resources to deliver repeatable, scalable and maintainable
to help you create and execute process safety solutions that meet solutions to help increase productivity, optimize plant assets and
or exceed your business goals. improve overall financial performance across your enterprise.

Certifications
• IEC 61508 – Functional safety of electrical/electronic programmable safety-related systems
• IEC 61511 – Functional-safety: Safety instrumented systems for the process industry sector
• NFPA 72 – National fire alarm and signaling code
• NFPA 85 – Boiler and combustion systems hazard code
• NFPA 86 – Standards for ovens and furnaces
• EN54 – Fire Alarm control panels
• EN298 – Automatic gas burner control systems for gas burners and gas burning appliances with or without fans
• EN50156 – Electrical equipment for furnaces and ancillary equipment: Requirements for application design and installation
• UL 508 – Industrial control equipment.

Rockwell Automation, Inc. (NYSE:ROK), the world’s largest company dedicated to industrial automation, makes its customers more
productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley® and Rockwell Software® product brands
are recognized for innovation and excellence.
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AADvance, Allen-Bradley, ControlLogix, ICS Triplex LISTEN. THINK. SOLVE, OptiSIS, PlantPAx, Rockwell Automation, Rockwell Software and Trusted are registered trademarks of Rockwell Automation, Inc.
CIP and EtherNet/IP are trademarks of Rockwell Automation, Inc.
All other registered trademarks and trademarks are property of their respective companies.

Publication PROCES-BR003A-EN-P – November 2015 Copyright ©2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.