Reliable, Flexible, Easy.Process Safety withSIMATIC Safety Integrated

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Process automation, with its extremely complex sequences, cannot afford to have any weak

links in the chain. Downtime and faults may have devastating effects – for people, equipment,

plants and the environment. To eliminate the source of hazards and minimize risks, you need

to have reliable safety technology for your processes that meets even the most stringent

demands: the Safety Instrumented System (SIS) of your choice should be reliable, flexible

and easy.

Reliable in eliminating risks – without stopping production.

Flexible offering flexible redundancy options and scalable architecture to economically

meet your requirements.

Easy to implement, operate and maintain.

A safe bet: highly available operationwithout any weak links

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Seamless safety technology ...

SIMATIC® Safety Integrated is a comprehensiveproduct range of safe, fault-tolerant and highlyavailable products for the process industries.Siemens safety systems enable early detection ofcritical signals, processing of those signals within apredefined logic and execution. It offers one of themost integrated systems available today, bridgingthe gap with regards to engineering and communi-cation tools over other conventional offerings.

... completely integrated into standardautomation

The SIMATIC S7-400FH automation system providesthe right mix of distributed I/Os to ensure maximumsafety, fault tolerance and availability for your appli-cations. In combination with the SIMATIC PCS 7process control system, you can realize powerful,flexible solutions for integrated automation andsafety applications in one, integrated automationnetwork.

Part of Totally Integrated Automation

With Totally Integrated Automation, Siemens is theonly provider of an integrated range of products,systems and solutions for automation in all sectorsof industry – from inbound logistics to outboundlogistics, from the field level to the manufacturingexecution level to the corporate management level.One part of Totally Integrated Automation is SIMATICSafety Integrated.

Something you can rely on

For more than 20 years, we have been a reliableindustry partner for first-class automation solutionsfor process safety – in a wide range of applications.Typical safety applications include fire and gas,burner management, emergency shutdown andcritical process control systems. Our solutions aredesigned to minimize engineering effort, enablingyou to lower your overall cost for meeting safetyrequirements. Our solutions comply both withapplicable national and international standardssuch as IEC 61508 (to SIL 3), ISA S84, EN 54,NFPA 85, API 14C and IEC 61511.

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A safe bet: reduced life cycle costswithout compromise

You expect a modern Safety Instrumented System (SIS) to consistently reduce the probability of dangerous

risks and to reliably execute safety-related functions. In addition, you expect redundant, fault-tolerant systems

to ensure process availability without downtime. Just as important is reliable self-detection of internal faults

and a guaranteed safe system state. In the unlikely event of a system fault, the diagnostic tools immediately

detect and localize the fault for quick repair. Although safety and reliability are the highest priority, economic

aspects of the solutions certainly play a big role in your decision.

Saves costs, space and installation overhead

With SIMATIC Safety Integrated, you benefit fromconsiderable savings potential – in different ways.Thanks to the coexistence of standard and safetyI/O modules in one system, you can cut down thenumber of hardware components, save separatewiring and reduce cabinet space. That saves theamount of spare parts you need to have on hand.Since you can use the proven PROFIBUS standardfor safe communication by utilizing the certifiedPROFIsafe profile, you no longer need a separatesafety bus.

Greatly simplified engineering

SIMATIC Safety Integrated makes engineeringmuch easier. You benefit from engineering tools,system diagnostics and operator interfaces. Youcan configure your safety functions for the SIMATICS7-400FH using our intuitive function block pro-gramming tool Continuous Function Chart (CFC)or the SIMATIC Safety Matrix for even more bene-fits. This easy-to-use configuration tool automat-ically generates complex safety programs basedon a cause & effects matrix, where the cause andeffects are easy to link. That means you can con-figure your safety logic much faster than before.

Maximum system availability

SIMATIC Safety Integrated offers systems with bothsingle and redundant design. Redundant systemsprovide you with maximum availability for yourequipment and plants right from the start. Our safetysystems ensure minimum unplanned downtimesduring operation and, accordingly, lower life cyclecosts. The safety-certified modules are completelyredundant internally, feature a diverse design andcan diagnose internal and external faults quicklyand effectively.

More flexibility

The modular design of SIMATIC Safety Integratedprovides a high degree of flexibility allowing forfuture modifications and expansions. Dependingon your requirements, the distributed I/O modulescan be equipped or expanded to include standardand safety I/O modules and can be combined in thesame station or separately. The system can be con-figured for SIL 2, SIL 3 or a combination of SIL 2 andSIL 3. This flexibility provides cost savings for appli-cations with a combination of SIL requirements.

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Easy integration into the process control system

You can connect our innovative Safety IntegratedSystem – SIMATIC S7-400FH and SIMATIC ET 200M/Sto any distributed control system (DCS). One of theunique features is the integration of safety functionsinto the SIMATIC PCS 7 process control system. Thiscombination also provides you with a number ofbenefits:

One engineering system for process control andprocess safety applicationsCommon controller platform for both processcontrol SIMATIC PCS 7 and process safetyUser-friendly display of process safety informa-tion integrated into the operator interface ofSIMATIC PCS 7Automatic integration of safety-related diagnosticsinto the operator interface, with time stampStraightforward and seamless communicationsbetween the DCS and SIS

A safe bet: well-designed anddetailed system architecture

SIMATIC Safety Integrated is a first-class Safety Instrumented System solution (SIS) based on

innovative and proven products, systems and standards. The highlight: you can easily connect

SIMATIC Safety Integrated to any control system – already integrated and harmonized with

SIMATIC PCS 7.

SIS – SIMATIC Safety Integrated

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Controller Safe, fault-tolerant and highly availableSIMATIC S7-400FH – configuration like for thestandard S7-400

SIL 3 can be met with only one controller

Standard and safety functions can be combinedin one controller or separately

Redundant S7-400FH controllers can be set upat separate locations – up to 10 km apart

Distributed I/O Two types of safety I/O modules: higher densitySIMATIC ET 200M with a large number of I/Omodules and bit-modular or lower densitySIMATIC ET 200S

NAMUR module of SIMATIC ET 200M for Ex areas

Expandable with standard and safety modulesdepending on your requirements

Safety-certified modules: are internally redundantand offer a diversified design

Comprehensive diagnostic functions for detect-ing internal and external faults

Safety functions are included in the safety I/Omodules

Communication Standard PROFIBUS DP with PROFIsafe profile

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We offer you engineering solutionsperfectly tailored to your individualrequirements.

Integration of SIMATIC Safety Inte-grated into SIMATIC PCS 7: engi-neering system SIMATIC PCS 7 withthe optional Safety Matrix packageincluding an integrated viewer 4

Connection of SIMATIC Safety Inte-grated with a third-party DistributedControl System: ContinuousFunction Chart 1 with the optionalSafety Matrix package

Continuous Function Chart (CFC)

The proven graphical engineeringtool from the Engineering System(ES) of SIMATIC PCS 7 lets you createstandard and safety functions. Thesafety logic is created by simply re-trieving and interconnecting TÜV-certified function blocks froma library.

Safety Matrix

Our Safety Matrix 2 features an inno-vative configuration tool implement-ing safety logic based upon a cause &effects matrix. A cause & effects matrixis often a result of a plant’s risk analysis.Specification of the safety programis simply completed by entering inputparameters for the safety matrix 3 .The Safety Matrix tool also providesfor simplified testing and trouble-shooting of the safety logic.

A safe bet: proven,innovative engineering

Continuous Function Chart (CFC) or Engineering System (ES) of SIMATICPCS 7 for configuring standard and safety functionality with officialTÜV-certified function blocks

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Configuration of analog or digital “causes” and digital “effects”

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The benefits of the Safety Matrixat a glance

Configuration of safety functions(logic) with the known cause &effects method – i. e. based on pro-cess events and process reactions

Automatic creation of thesafety logic

Minimization of programming mis-takes thanks to easy and transpar-ent configuration

Automatic generation of documen-tation after safety reviews

Shortened configuration times,since no special programmingknowledge is required

Automatic generation of cause &effect matrix and user-friendly dis-play of the safety matrix on the op-erator interface of SIMATIC PCS 7

Automatic management of projectversions

Easy tracking of changes

Straightforward, online changes tosafety functions and easy adapta-tion of logic in test mode, as wellas maintenance functions such asbypass, reset and override

Safety Matrix: “Intersections” define the link between “cause”and “effects”

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User-friendly visualization of the Safety Matrix at the operatorstation (OS) with SIMATIC PCS 7

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Oil and gas: Statoil offshore platform, Norway

Statoil, the largest Norwegian petroleum corporation, relieson a combination of fire and gas alarm systems and emer-gency shutdown systems to reliably meet all the criticalsafety requirements for its unmanned Huldra offshore oilplatform in the North Sea. One reason for this: the previouslyinstalled SIMATIC S5 has a proven record of past reliability.

The solution5 SIMATIC S7-400FH controllers

3000 safe inputs and outputs via SIMATIC ET 200M

Plant configuration

The project marked the beginning of a new generation ofautomation controllers with integrated safety engineeringat Statoil. Since then, 20 more platforms have been equippedwith SIMATIC S7-400FH. Statoil further leveraged its costsavings by reusing the user programs on all the platforms.

Chemicals: production of plant protection productsat Bayer in Dormagen, Germany

At its new multipurpose plant in Dormagen, it was especiallyimportant for Bayer CropScience AG to establish an inte-grated system with SIMATIC PCS 7 from the field level tothe ERP level (SAP). Bayer decided on a control systemsolution with integrated safety engineering – for 35 processengineering plants, 240 subsystems and 4500 measuringpoints.

The solution SIMATIC PCS 7 process control system with SIMATICSafety Integrated

53 SIMATIC S7-400FH controllers

1000 safe inputs and outputs via SIMATIC ET 200M

Plant configuration

SIMATIC Safety Integrated has led to a reduction in engi-neering costs over the entire life cycle of the new multipur-pose plant. Thanks to the high degree of flexibility, produc-tion can be adapted to changing requirements much moreeasily and quickly. Based on assignment of controllersaccording to specific subsystems, i. e. one controller persubsystem, it is much easier to perform maintenance workand modifications.

A safe bet: references in the process industry

Statoil offshore platform, Norway

Bayer in Dormagen, Germany

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Whether it’s refineries or petrochemicals, oil and gas, chemicals, pharmaceuticals: based on our sound know-

how and our comprehensive experience, we have already implemented a wide array of turnkey solutions in

the process safety segment. These solutions have proven their worth in everyday use around the world.

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Refinery: Shell Deutschland Oil in Heide

When modernizing and restructuring its refinery in Heide,Shell Deutschland Oil was basically pursuing the followingobjectives: greater efficiency and products that meet therequirements of the market – now and in the future. Theplant solution needed to include a combination of bothstandard and safety distributed I/O modules – in an auto-mation system that is highly available and at the same timea safety automation system.

The solutionSIMATIC PCS 7 process control system with SIMATIC SafetyIntegrated

22 SIMATIC S7-400FH controllers

25 % of the entire distributed I/O are safe inputs andoutputs via SIMATIC ET 200M

Plant configuration

SIMATIC Safety Integrated is a winning solution from anyperspective – as a secure investment, for integration,scalability, user friendliness and its modular design. Theopenness of SIMATIC PCS 7 enables easy vertical integrationof the ERP level via standardized interfaces. In addition, themodernized plant can be configured, diagnosed and main-tained much more efficiently and quickly right to the fieldlevel – online via PROFIBUS.

Refinery: Repsol YPF in Tarragona, Spain

Another project where Siemens has proven its sector exper-tise was the automation of the new hydrocracker for RepsolYPF at its refinery in Tarragona, Spain. The hydrocrackeritself refines an impressive daily throughput of 24,000barrels of petroleum, turning it into high-quality products.The demands on the SIS were just as impressive. The tasksinclude locking the two ovens, motorized controllers andregulation of the tank fill level as well as emergency shut-down for five compressors for controlling the ventilationflue and the ovens.

The solutionSIMATIC PCS 7 process control system with SIMATIC SafetyIntegrated

2 SIMATIC S7-400FH controllers

1900 safe inputs and outputs via SIMATIC ET 200M

Plant configuration

The two SIMATIC S7-400FH controllers ensure that theplant is operating in the “green range” at all times. Withthe new hydrocracker, Repsol YPF was able to increase itsproduction of gasoline, diesel and other high-qualitypetrochemical products considerably. Of course, the fuelsfrom Tarragona also comply with the new environmentalguidelines of the EU.

Repsol YPF in Tarragona, Spain

Shell Deutschland Oil in Heide

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You want to know more?You can find more information on the Internet:

The information provided in this brochure contains merelygeneral descriptions or performance characteristics, which incase of actual use do not always apply as described or whichmay change as a result of further development of the products.An obligation to provide the respective characteristics shallonly exist if expressly agreed in the terms of contract.

SIMATIC Safety Integrated:www.siemens.com/fh-cpu

SIMATIC PCS 7:www.siemens.com/simatic-pcs7

Safety Integrated:www.siemens.com/safety

Totally Integrated Automation:www.siemens.com/totally-integrated-automation

Download and order info material:www.siemens.com/simatic/printmaterial

SIMATIC Partners:www.siemens.com/automation/partners

Order online – A&D Mall:www.siemens.com/automation/mall

Service & Support:www.siemens.com/automation/service&support

w w w . s i e m e n s . c o m / a u t o m a t i o n

SIMATIC is a registered trademark of Siemens. Other designationsused in this publication may be trademarks whose use by thirdparties for their own purposes could violate the rights of theowners.