A World Class Safety Instrumented System (SIS) for Dependable Plant Safety
The ProSafe-RS Safety Instrumented System is a TÜV certified Safety Instrumented System (SIS) for use in SIL 1, 2, and 3 applications in a single modular configuration, with superior availability in a redundant configuration. It can be a standalone system or tightly integrated with our CENTUM VP Distributed Control System.
Yokogawa industrial safety systems minimize interruptions with:
- Highly reliable protection at all SIL levels
- Real-time dashboard, quantifying current and future risks
- Virtual scenario testing to assess the impact of future bypasses and overrides
- Online modification, which allows plants to continue to run during upgrade
- Automated compliance reporting to optimize testing frequency
- Cradle to grave service and lifecycle assurance
Here are the top 10 reasons why ProSafe-RS is the fastest growing safety control system in the global market.
ProSafe-RS Top 10 Features & Benefits
1. Maximum Fault Tolerance
As the last line of defense, the safety controller must act reliably exactly when it needs to. Yokogawa's exclusive Versatile Modular Redundancy maintains unlimited SIL 3 operation even under multiple failure scenarios. This reliability by design allows ProSafe-RS to continue operating long after other safety systems would have failed.
2. "On the Fly" System Changes and Expansion
The high-efficiency ProSafe-RS engineering environment allows online software changes and system expansion while the safety function continues operating. No shutdown is necessary.
3. The Power of One
Our integrated control and safety architecture minimizes CAPEX and OPEX costs. It maintains safety control segregation while providing a common operator environment, common system maintenance, precise time synchronization and sequence of events analysis for DCS and SIS functions.
4. Made to Measure
Users can rely on Yokogawa for all functional safety and risk reduction needs. Yokogawa ProSafe-RS has the unique ability to scale from small process units to complex petrochemical and offshore production applications. Plus, its IEC 61508 type approval spans SIL1 to SIL3.
5. First Globally Certified Functional Safety Management Solution
Yokogawa’s Functional Safety Management solution is TÜV certified according to IEC 61508 and IEC 61511 Edition2 2016. This solution supports a clear functional safety policy that complies with international standards.
6. Interoperability
ProSafe-RS can interoperate with a broad range of control, SCADA and PLC systems. When used with Yokogawa’s systems, standard displays, faceplates and database compatibility substantially reduce project execution costs and user learning curves.
7. Asset Management Integration
Unlike most Safety Controllers, ProSafe-RS provides integral asset management support. It can communicate I/O and HART information directly to Yokogawa’s Plant Resource Manager without the need for a separate multiplexer. Integrated safety health checks include scheduled partial stroke valve testing.
8. Software Configurable Remote I/O
Network I/O enables automated commissioning by decoupling application engineering from field wiring. Software configurable I/O modules at the edge eliminate marshalling and reduce wiring by up to 80%. Plus, last-minute I/O changes require no new hardware and keep the project on schedule.
9. Integral Cyber Security
Today’s high demand for plant connectivity and information has resulted in a substantial increase in cyber threat vectors. With built-in security measures by design and certified by all global industry security standards, Yokogawa's ProSafe-RS continually undergoes rigorous testing in our global cybersecurity lab to ensure maximum protection.
10. Sustainable Safety Lifecycle Solution
Yokogawa’s comprehensive safety lifecycle management solution simplifies compliance and reduces both CAPEX and OPEX. It provides Process Hazards Analysis services and solutions, an intuitive user interface, improved safety integrity reports and automated change management.
Details
What is a Safety Instrumented System?
Safety Instrumented Systems aim to ensure industrial processes' security by engineering sensor, control, and logic integration.
Industrial Applications of Safety Instrumented Systems:
- Chemical
- Petrochemical
- Refinery
- Electric Power
- Emergency Shutdown
- Burner Management
- Fire and Gas
Resources
- A certified emergency shutdown system
- Substantial reduction in maintenance work
- System configuration with reduced footprint
- System scalability
- Meet the IEC 61508/JIS C 0508 functional safety standards
- Proactively introduce leading edge technologies
- Accommodate the plant licensors' safety, reliability, and maintainability requirements
- Improve the monitoring and operation functions of the emergency shutdown system
Nitrogen Fertilizer Manufacturer Cyber Security Implementation Success Story
- Operational Excellence by Asset Maximization, Utilizing Yokogawa's DCS, SIS, Analyzers, and Field Instruments.
- The CENTUM VP PCS and ProSafe-RS SIS were integrated using the same engineering environment.
- Nearly 60 gas chromatographs and a large number of other types of analyzers in several analyzer houses.
- Integrated CENTUM VP and ProSafe-RS Systems Ensure Nonstop Operation of ADU/DKU Processes.
- "This is a real VigilantPlant! We will continue to improve our production efficiency."
- Rapid Implementation of Integrated CENTUM DCS and ProSafe-RS.
- The highly reliable CENTUM DCS system has also helped TOL maintain high productivity at this plant.
- Modern waste to energy facility in UK uses CENTUM CS 3000 and ProSafe-RS
- Lakeside exports at least 34MW per hour to the country's national grid
- As the main automation contractor (MAC) for this plant construction project, Yokogawa Brazil engineered, installed, and commissioned an integrated control and instrumentation solution
- Yokogawa Brazil completed the commissioning of these systems ahead of schedule and the production of green polymer was started just one week later
- OTS for familialization of liquefaction processes and operator training.
- Yokogawa's integrated solutions contribute to safe and steady production at gas liquefaction plant in Norway.
- World's first offshore regasification terminal relies on Yokogawa ICSS (CENTUM CS 3000, ProSafe-RS).
- LNG carrier scheduling, unloading, tank storage, and vaporizing are all procedure based operations.
- A robust and reliable integrated control and safety system (ICSS) made up of the CENTUM CS3000 PCS and the ProSafe-RS SIS ensures safe operations while fully automating key processes.
- A variety of analytical instruments accurately measure the concentrations of key components, and this data can be monitored and controlled by the Yokogawa PCS.
Yokogawa Romania successfully modernized the control system at ELCEN's combined cycle heat and power plant.
A major challenge in deploying the system when all work moved to the virtual space was the Covid-19 pandemic.
- Yokogawa supplied control, monitoring, and protection systems for plant modernization.
- Fine engineering and Yokogawa's products made successful operation without any problem or shutdown.
- Legacy ProSafe-PLC SIS replaced with ProSafe-RS to improve sustainable lifecycle support at LNG terminal.
- The seamless use of the same HMI for both PCS and SIS, and improved safety and integrity.
- FDT compliant FieldMate manages a wide variety of digital process instruments of multi-vendors.
- The SNF engineers can manage the complete lifecycle of assets and configure devices by using FieldMate.
- DCS, SIS, PRM with FOUNDATION fieldbus and OTS Installed in Thailand First LNG Terminal.
- Alarms are issued before any device fails completely, enabling predictive maintenance that reduces maintenance costs throughout the facility lifecycle.
Yokogawa provided integrated control and safety system to Banagas's CGP-3 gas processing plant.
N-IO based system contributes to reducing maintenance and other operating expenses (OPEX).
GC8000 was selected to detect components responsible for stainless steel corrosion of pipeline.
GC8000 with custom container analyzes crude oil components every 4 mins at an offshore platform.
The Mathura refinery is a strategically important facility that supplies diesel, gasoline, aviation turbine fuel, kerosene, liquefied petroleum gas, furnace oil, and bitumen to customers throughout northwestern India.
- Integration of CENTUM CS 3000 with ProSafe-RS improves plant safety and reliability.
- Yokogawa's PRM package manages more than 500 HART field devices including control valves.
- Completion of First FPSO Project for Prosafe Production Services Pte Ltd
- Integrated Control & Safety System (ICSS) makes possible centralised plant supervision and management of all control and safety functions on this FPSO.
To enable central control of the entire plant, all of its subsystems are integrated with Yokogawa's CENTUM VP DCS.
- HMEL selected an integrated solution from Yokogawa
- Yokogawa India oversaw and implemented the engineering, installation, and commissioning of the refinery
In maintaining and managing industrial plants, monitoring waste water pH/ORP is both a legal obligation and an unavoidable necessity for protecting the environment. Monitoring without an attentive eye can lead to severe consequences.
Process automation end users are under more pressure than ever to do more with less. The current economic climate means that many automation capital projects are on hold. With capital budgets tighter than ever, users instead focus on operational budgets (where cost cutting is also a key concern), or on automation investments with a very rapid return on investment.
- Biofuel
- Biomass Power
- Chemical
- Drinking Water Treatment
- Energy Transition
- Geothermal Power
- Iron & Steel
- Mining & Metal
- Offshore (FPSO FLNG & FSRU)
- Oil & Gas
- Oil & Gas Downstream
- Petrochemical
- Pharmaceutical
- Power
- Pulp & Paper
- Refining
- Specialty & Fine Chemical
- Thermal
- Upstream
- Waste to Energy
- Water & Wastewater
Asset health monitoring has long been in existence to protect expensive equipment and/or operations from costly, critical, or catastrophic failures, with numerous examples in nuclear, aeronautical, petrochemical, industries and beyond. The costs associated to install the sensors and asset health system way overcome the consequences of not implementing. However, this is not the case in all industries, with all equipment and/or all operations. In many cases equipment is run until failure and then repaired or replaced.
Hydrogen (H2) production through electrolysis has emerged as a key technology in the transition towards sustainable energy, especially when powered by renewable energy sources like wind, solar, and nuclear. However, optimizing this process for efficiency and cost-effectiveness requires integrating various components, packages, and control systems within hydrogen plants.
The whitepaper discusses the importance of safety culture in achieving a smarter and safer working environment. It highlights statistics on work-related accidents and diseases, the cost of poor safety culture, and the need for a true safety culture achieved through company leadership.
Yokogawa has come a long way in making its message clear to the world of process automation. Last year, the company embarked on a full-scale global marketing campaign to make customers aware of the company's focus on system reliability, security, dependability, and robustness. Dubbed "Vigilance", the campaign created a unified message for the company and greatly helped expand awareness of the Yokogawa brand and corporate philosophy.
- Biofuel
- Biomass Power
- Chemical
- Drinking Water Treatment
- Energy Transition
- Geothermal Power
- Iron & Steel
- Mining & Metal
- Offshore (FPSO FLNG & FSRU)
- Oil & Gas
- Oil & Gas Downstream
- Petrochemical
- Pharmaceutical
- Power
- Pulp & Paper
- Refining
- Specialty & Fine Chemical
- Thermal
- Upstream
- Waste to Energy
- Water & Wastewater
Network and system security is now a necessity in process automation industry. YOKOGAWA provides a service lifecycle solution for cyber security to ensure that the security measures and deployments are continuously enhanced, monitored and inspected.
This white paper explains the details of the security design, implementation, operation and validation solutions from the technical perspective.
Recently, several ARC Advisory Group analysts and management team members had a chance to sit down with the new Yokogawa President and COO, Mr. Takashi Nishijima, and several other top Yokogawa executives to discuss the company's burgeoning presence in the worldwide upstream and midstream oil & gas industry.
Due to emerging competitors from the rapidly growing countries such as India and China and the global economic downturn triggered by the Lehman shock, many companies in the process industries are struggling to survive the severe global competition.
This article will not get into evaluating potential safety hazards or designing safety systems, which are extensively covered elsewhere. Instead, we will discuss ways of interpreting and implementing the findings of these evaluations.
Migration of a refinery's DCS provided an opportunity to reconfigure and consolidate the control rooms and operational management system.
September 2006
Launched in February 2005, Yokogawa's ProSafe-RS safety instrumented system (SIS) quickly gained a significant share of the market. Just 18 months later, 100 units had been sold-quite a feat considering the generally conservative nature of the SIS market. So what is behind this rapid success?
April/May 2007
A Yokogawa ProSafe-RS safety instrumented system (SIS) will be the nucleus of a new fire and gas safety system at Shell's Clyde (NSW) refinery. The contract includes the control system, system engineering and installation and supervision.
LNG Industry, Summer 2012
Martin te Lintelo, Yokogawa, The Netherlands, discusses the need for better automation, measurement and control instruments to cope with the rising popularity of LNG.
Downloads
Brochures
- Migration from ProSafe-PLC to ProSafe-RS (1.6 MB)
- CENTUM VP DCS Top 10 Features Infographic (231 KB)
- Safety Instrumented System ProSafe-RS (6.3 MB)
- Solutions for the Chemical Operations Executive (1.2 MB)
- ProSafe-RS N-IO (Network I/O) (1.2 MB)
- ProSafe-RS Standalone SIS (3.1 MB)
- ProSafe-RS Partial Stroke Test (PST) (1.1 MB)
- Sustainable SIS (7.3 MB)
- Product Poster (751 KB)
Certificates
- TÜV SIL3 Certificate (645 KB)
- ISASecure™ Embedded Device Security Assurance Program 2010.1 (117 KB)
- TÜV SIL3 Certificate - ProSafe-RS R4.10 (664 KB)
- Bureau Veritas: Marine and Offshore (5.2 MB)
- Hazardous Approvals: Certificate of Conformity (515 KB)
- ABS Certificate of Design Assessment (2.4 MB)
- DNV GL Certificate for Ships. Offshore Units, and High Speed and Light Craft (174 KB)
- Lloyd's Register Certificate (378 KB)
Videos
Yokogawa South Africa was appointed to design, supply and commission the Integrated Control and Safety System (ICSS) as well as the overall Terminal Management System at Sunrise Energy’s liquid petroleum gas (LPG) Import Terminal, the largest on- and offshore open-access LPG import terminal facility in Africa. Yokogawa’s Terminal Management System, Terminal Logistic Suite VP (TLSVP), was designed and developed to meet the exacting operational demands and logistic needs in terminals. Yokogawa’s experienced engineering resources ensured the project was successfully delivered, enabling Sunrise Energy to provide accurate mass balances and efficient terminal operations to its customers.
News
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Press Release Jan 11, 2022 Yokogawa Enhances Cybersecurity and Safety for the OpreX Control and Safety System Lineup
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Press Release May 23, 2021 Yokogawa Obtains ISASecure CSA Level 1 Certification for ProSafe-RS Safety Instrumented System, a Product in the OpreX Control and Safety System Family
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Press Release Apr 11, 2017 Yokogawa Releases Enhanced Version of ProSafe-RS Safety Instrumented System
- Easy adoption and use as a fire and gas system -
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Press Release Jul 14, 2016 Yokogawa Wins Major Refinery Control Systems Order from S-Oil Corporation
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Press Release Jun 10, 2016 Yokogawa Corporation of America Announces TÜV Rheinland Certification for Functional Safety Management
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