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A Safety Layer for Foundation Fieldbus

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A Safety Layer for Foundation Fieldbus UNIVERSITY OF OSLO Department of Informatics A Safety Layer for Foundation Fieldbus Henrik Tobias Brodtkorb Cand. scient. thesis 6th of May 2001 Summary The focus of the work of this Cand. scient. thesis has been placed upon understanding and developing a concept for using digital communication in safety-critical applications. It is increasingly common to use programmable technology in a safety-critical control system. These new software-based components are in many cases replacing existing hard-wired and analogue components that have safety-critical functions. Implementing these software-based safety-critical systems require more in-depth methods and concepts than what traditionally has been used in software engineering. I have concentrated my studies around problems concerned with using fieldbus technology between the subsystems in a software-based safety-critical system. During the work on this thesis I have had to acquire a substantial amount of knowledge about subjects not previously covered in my studies. I have gained knowledge about industrial process control systems, safety-critical systems, international IEC standards for safety systems, various fieldbus technologies, coding theory and hardware related programming. The basic knowledge required to appreciate the contents of this thesis is presented as background information in the introductory chapters. One of the main goals of this thesis has been to analyse and find out if it is possible to implement a safe communications protocol for Foundation Fieldbus fulfilling the stringent requirements of a SIL 3 application. My studies are based on a concept of a general communication protocol called a “Safety Layer.” A safety layer defines methods for increasing the probability of detecting errors that may occur between two communicating fieldbus devices. The safety layer’s objective is to make the transmission “safer” between two nodes in a fieldbus network. This involves enabling the communication parties to determine that messages have the right value, they are sent in the correct sequence and to the right time and have correct origin/destination. In my thesis I have further developed the basic idea behind the safety layer in a general sense so that it can in principle be used on top of any communication protocol to provide safe communication. This study has furthermore been extended with an implementation of a safety layer prototype for Foundation Fieldbus. The purpose of this implementation is to demonstrate how Foundation Fieldbus can be made safer and that the concept and ideas of the general safety layer are feasible. The protocol incorporates a method for enabling two-way communication between two function blocks and new CRCs for improved error detection. The choice of generator polynomials for these CRCs has been based on probabilistic considerations. The safety layer also specifies a communication mode that sanctions transmissions of amounts of data larger that the maximum allowed transmission unit. The implementation of the safety layer is unique in its kind. Similar work has never before been done for Foundation Fieldbus. I do not assume any liability for any accidents, loss or damage caused as a result of any errors or omission in this thesis. Acknowledgements I would like to thank my supervisor at the University of Oslo, Department of Informatics, Associate Professor Tor Skeie for his support and guidance throughout the whole process of writing this thesis. I would also like to thank Scientist Lars Lidström at ABB Corporate Research AS in Norway for giving me a flying start on my project and for his assistance during the work. Additionally I would like to thank Jan Endresen at ABB Corporate Research AS for his help on problems related to the CRCs. I must also thank my other friends and colleagues at ABB for many rich and helpful discussions and the encouraging words along the way. I am grateful to the support group at National Instruments and Tom Boyd at Fieldbus Inc. for their patience and for the help they offered me on technical problems with the development tools. 5 Contents Summary ............................................................................................................................. 3 Acknowledgements ............................................................................................................. 5 Contents............................................................................................................................... 7 List of Tables..................................................................................................................... 11 List of Figures ................................................................................................................... 13 Chapter 1 Introduction ................................................................................................... 15 1.1 Problem domain .................................................................................................... 15 1.1.1 Safety Systems .............................................................................................. 16 1.1.2 Technological Trends of Safety Systems...................................................... 19 1.1.3 Commercial Dimensions of Safety Systems ................................................. 20 1.1.4 The Evolution of Process Control Systems................................................... 21 1.1.4.1 The eight parts of IEC 61158 .................................................................... 22 1.1.5 The Benefits of Adopting Fieldbus ............................................................... 25 1.1.6 ProfiSafe........................................................................................................ 27 1.2 Problem specification............................................................................................ 29 1.3 The structure of this thesis .................................................................................... 32 Chapter 2 Foundation Fieldbus...................................................................................... 33 2.1 FF - Fieldbus Foundation or FOUNDATION Fieldbus?...................................... 33 2.2 Foundation Fieldbus vs. the OSI Reference Model .............................................. 33 2.3 Foundation Fieldbus System Architecture ............................................................ 35 2.3.1 FF Communication Stack.............................................................................. 36 2.3.1.1 Physical Layer........................................................................................... 36 2.3.1.2 Data Link Layer (DLL)............................................................................. 38 2.3.1.3 Application Layer...................................................................................... 39 2.3.2 User Layer..................................................................................................... 41 2.3.2.1 Function Blocks......................................................................................... 42 2.3.3 Function Block Shell..................................................................................... 44 2.4 Development of a FF Device ................................................................................ 45 Chapter 3 IEC 61508 ..................................................................................................... 49 3.1 Risks in Industrial Processes................................................................................. 49 3.2 What is the IEC 61508 standard?.......................................................................... 50 3.3 Safety Integrity Levels ..........................................................................................50 3.4 Other standards and regulations ............................................................................ 53 Chapter 4 Safety Critical Communication..................................................................... 55 4.1 Risk Considerations For Safety Critical Communication..................................... 57 4.2 Communication failure modes outlined in IEC 61508..........................................58 4.2.1 The IEC 61508 communication failure modes related to the standard FF communication protocol............................................................................................ 59 4.2.1.1 Data corruption.......................................................................................... 59 4.2.1.2 Corruption of sender and/or receiver addresses ........................................ 59 4.2.1.3 Inaccurate timing of transmission of data packages.................................. 60 4.2.1.4 Wrong sequence of packages .................................................................... 60 4.3 Principle Solution For Safety Critical Communication ........................................60 4.3.1 The Safety Layer ........................................................................................... 61 7 Chapter 5 The “Safety Layer” for Fieldbus Foundation................................................ 63 5.1 The Safe Function Block Concept ........................................................................ 64 5.2 Safe Function Block Specification........................................................................ 67 5.2.1 Safety Frame ................................................................................................. 68 5.2.2 Fields ............................................................................................................
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