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BROCHURE
HiaGuard Safety Instrumented System
Safeguarding Your Production, Optimizing Operational Efficiency
Contents
Overview 03
System Application 05
System Architecture 06
SystemHardware 09
System Monitoring Software 11
Advanced Configuration Software 13
Services 15
Typical Cases 16
Appendix 21
Overview
Providing Safety Assurance for Your Production
HiaGuard SIS (Safety Instrumented System) is developed by HollySys and specifically designed for the industrial automation safety sector It has been certified by TUv Rheinland in Germany.The system adheres to IEC 61508 and IEC 61511 standards, achieving SC3 system capability and SIL3 safety integrity levels,making it suitable for safety-related applications.
Since its launch, HiaGuard SIS has been implemented in thousands of functional safety scenarios across various industries worldwide, including refining and petrochemicals, coal chemicals, oil and gas production, storage and transportation, energy and power generation, metallurgy, papermaking,food and pharmaceutical among others. The system is committed to leveraging cutting-edge technology to enhance the safety and reliability of production units while providing customers with excellent safety assurance and operational efficiency.
High Availability
HiaGuard SIS adopts 2oo3 (2-out-of3 with Diagnostics technology, ensuring outstanding advantages in safety, stabilty and real-time performance.Additionall, the system upports 3- degradationmode, ensuring continued availability underabnormal conditions,with availability reaching upto99.999%.
Safety Compliance
The system meets international safety standards IEC 61508 and IEC 61511SC3 system capability level and SIL3 safety integrityvelthasreceivedcertificationfrmTRheinlandinGermanyaswellasECertification(includingMad LVD),G3 Anticorrosion Certification,CCS,and Achilles Certification.
AccurateDiagnostics
HiaGuard SIS offers comprehensive diagnostic capabilities with a diagnostic coverage of over 90% allowingprecise fault localization down to the channellevel.ts 1msresolution Sequence of Events(SOE)recording accuratelycaptures operationaldetailheapplicationof thHRTprotocfacilitatseasiecalbationandmaintenance of fieldinstrment.
Integrated Safety
HiaGuardScanbeseamlesslyintgrated withHollysDCSthroughaunified sstemetworksharingphysicaetor resourcesbtmaintaininglgicalseparationwithdifferent protocolsfailureontheDCSsidedoesnotmpactSISsafty Operatorscanaccessreal-tiedatafrmbothSandSIviaumamachineintefcesmlifyingdataacquisitionand managementprocesses andreducingsoftware andhardwarecosts.
Protocols and Interfaces
HiaGuardSISiscompatiblewithProfibusTCP/,andModbuscommunicationprotocolsltusesRS485andEthernet interfaces to enable one-way ortwo-way data exchange with othersystemsviacommunication stations orwitches.
Secure Communication
CommunicationbetweenHiaGuard systemstationsadoptsasafetycommunicationprotocolthat complieswithfunctional safety standards.It employs black channeltechnologytoforward and transmit safetydataviacommunicationmodles and switches, ensuring data security.
System Application
Enhancing Operational Reliability of Critical Facilities
HiaGuard SIS adopts 2oo3D (2-out-of-3 with Diagnostics) technology, suitable for the following applications:
System Architecture
Flexible Architecture for Efficient and Safe Management Across Industries
HiaGuard SIS mainly consists of engineering stations, operator stations, historian stations, and control stations, forming the system network and control network. The control network's nodes consist of control stations and I/0 modules. HiaGuard SIS supports up to 15 domains, each supporting 64 control stations, with each single station supporting a maximum of 1,856 I/0 points. The main rack supports up to 224 1/0 points.
2oo3D (2 out of 3 with Diagnostics) Technology
HiaGuard SIS employs 2oo3D (2 out of 3 with Diagnostics) technology, incorporating triple redundancy, selfdiagnostics, and a 2oo3 voting mechanism to significantly enhance safety and stability,meeting diverse user needs.
HiaguardachevesfultriplicationacrssinutmdlecontrolleandoutmodulCmentsuchascontrler /modles,teminal boardsntworkcommunicatiomodandsafetyoopsmeet SIstandards accordin t5
Triple-Redundant Controllers and Control Bus: The system uses three independent controller modules that operate synchronously, with the controllers exchanging data via the CPU bus using a safety communication protocol.
Triple-Redundant and Hot/Standby I/O Modules: Each I/O module is equipped with three independent control buses. The modules are independently configured to meet SIL3 requirements of IEC 61508, and they can be configured redundantly for increased availability.
SIL3 Safety Loops: Data exchange between each controller and its corresponding I/O module uses a safety communication protocol. The safety loop complies with SIL3 requirements of IEC 61508.
2003 Voting Mechanism: The output module contains three parallel hardware channels, ensuring reliable output data through a 2oo3 voting mechanism.
| BasicEnvironmental Indicators | |
| Working environment temperature | -10 to 60℃ |
| Operating environment relative humidity | 5% to 95% relative humidity, non-condensing |
| Storage environment temperature | -40 to-80℃ |
| Storageenvironment relative humidity | 5% to 95% relative humidity, non-condensing |
| Vibration | Accelerated speed:0.5 g,vibrationfrequency:10 Hz≤f≤150 Hz |
| Environmental adaptability | Compliant with ISAS71.04 G3 |
| ElectromagneticCompatibilityRequirements | |
| Electrostatic discharge immunity | Compliant with IEC 61000-4-2 +6 kV contact discharge, ±8 kV air discharge |
| Radio frequency electromagnetic field radiation immunity | Compliant with IEC 61000-4-3 20 V/m (80 MHz to 1 GHz), 10 V/m (1 GHz to 6 GHz) |
| Electrical fast transient burst immunity | Compliant with IEC 61000-4-4 5/50 ns waveform, AC power port 4 kV, signal port 2 kV at 5 kHz and 100 kHz |
| Surge (shock) immunity | Compliant with IEC 61000-4-5; AC power port common mode 4 kV, differential mode 2 kV, signal port common mode 2 kv |
| Radio frequency field Induced conducted disturbance immunity | Compliant with IEC 61000-4-6 20 V, 150 kHz to 80 MHz |
| Power frequency magnetic field immunity | Compliant with IEC 61000-4-8 Steady-state100A/m,transient 300A/m |
| Voltage dips and short interruptions immunity | Compliant with IEC 61000-4-11 AC power port dips to 0% for 1 cycle, 40% for 10 cycles, 70% for 25 cycles, 80% for 250 cycles;short interruptions for 250 cycles |
| Radiated emission, conducted emission | Compliant with IEC 61131-2, EN 61000-6-4,Class A |
| System Specification | |
| Maximum number of domains | 15 |
| Maximum number of operating stations per domain | 64 |
| Maximum number of field control stations per domain | 64 |
| Maximum number of I/O modules per station | 58 pairs |
| Maximum number of I/O points per station | 1,856 points |
| Real-TimeResponseCapability | |
| SOEresolution | 1 ms |
| Operator station data refresh time | |
| Operator station command issuance time | |
| High Security | |
| Certified toIEC61508standard forfunctionalsafetySIL3/SC3 | |
| Full hardware redundancy and fault tolerance, no single point of failure | |
System Hardware
Advanced Hardware Provides High Reliability, Stability, and Safety for Critical Operations
Controller
Communication Module
■TMR (Triple Modular Redundancy) architecture adopted
■Three physically independent controllers
■Facilitating data exchange between the controller level and the operator stationlevel ■ Providing system time synchronization ■Supporting redundant configuration
■Data exchange between controllershandled bycontrol bus ■Input and output data voted on by the three controllers
■Built-in firewall to network storms anc ■ Equipped with Mod data communicatio
1/0 Module
Power Supply Module
protect against external Iviruses Ibus interface to support n with third-party devices ■Supporting online replacement ■SOE(Sequence of Events) accuracy up to 1 ms
■Single I/O module with physical triple redundancy Supporting hot/standby redundant configurations
■ 1:1 redundant power supply configuration
■Isolation of system power and field power
System Monitoring Software
Intuitive Interface and Real-Time Monitoring for Enhancing Operational Efficiency and Decision Accuracy
HiaGuard SIS monitoring software simplifies plant operations by providing timely information crucial for decision-making. Its intuitive interface allows users to easily understand operational status and take appropriate actions. The system assists operators inquickly finding proactive solutions,reducing the pressure of time-sensitive situations and ensuring safety in critical moments.It seamlessly integrates with DCS, CCS, and other control systems.
User-FriendlyHuman-Machine Interface
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One-Click Navigation Function
Eachdevice ormeasurement point isequipped withauniquelydesigned panel that allows one-click accesstoallrelated functions, suchas alams,trends, anddetaild infrmation perators caneasilymanage comlexsituations with confidee.
Trend and Alarm Management
Alarmscanemanagedyregiongroup,rtmpifyinerationsustomizalealamiconsandcolchememii distractions and improve eficiencyTrend tracking hels sers anticipate system performance changesver time gainng valuableperationalinsigtsandmakinginformedecisionswhilensuringeffcincyandprecisioninadressinoeration challenges.
SOE Query
TheSOEquerfunctionalwsSOErecordstobesearchedbytimeandsupportstheeport andprintingofSOEevent reord
Real-Time Online Download
Operatorscanperfrmrealtiedwladsnliwithout disturbinprductionmaximiinproductivityandfleibit softwareallwsfrmodificationdwladsanddebugginguringperationwithouttheeedforhtdwscrment compilationand dwloading redcedisruptions,enabling mooth transitionsandoosting efficiency ensuring thehghest operational performance and quickest response speed.
Interlock Diagram
History Record
Advanced Configuration Software
Simplifying Management with an Intuitive Interface and Flexible System Customization
HiaGuard SIS' advanced configuration software, Safe-AutoThink (Safe-AT) developed by HollySys, is specifically designed for Safety Instrumented System (SIS). As a critical component for control logic in HiaGuard SIS, Safe-AT meets the SIL3 tool requirements of IEC 61508. Combining cutting-edge technology with a user-friendly interface,Safe-AT provides precise and effcient monitoring and management capabilities, ensuring the safe and reliable operation of your industrial processes. ts flexible scalability also supports future system upgrades and functional expansions.
Graphical ManagementandReal-TimeMonitoring
Projectsaremanaeduinatreestrtureprovidingaerarchyandefficietmangmenaf-prtsra configuratinfr tak set prgramardware configuratios arial dinitions,andMdhinuiti interfacemaksperationsinlmnitoringdeerscaneasilyvitheperatioalstatusndalaminfmat of modules,check module versiondetails quickly, and enhance thereal-timemanagement and control experience.
Flexible Logic Language and Programming Methods
Safe-AT offers three IEC 61131-3 compliant safety programming languages: Ladder Diagram (LD), Function Block Diagram (FBD), and Structured Text ST).These languages enable users to mplement various logic solutions.The system supports automaticdecompilationtoensureconsistencybetween source and target projects,llwing userstoperform configuration verification to confirm the correctness and completeness of the program.
Offline Simulation Function and Debugging
Safe-AT enables contrlle and HMI simulation allowing for programlogic debugging and interlock lgicmodifiations in thecontroller simulationenvironmentsignificantlyreducingonsitecommissioningeffortsTheHMIsimulationplatform providesreal-timinterfacedesiganderinteractionsiulation,ensurin theusabityandfnctionalitf theperato interface.
SecurityPermissionFeatures
InSafe-different vesofuepemissionsareet frvariuscontrolleperationsandaccessrights.erationh as downloading programs starting/stopping IEC tasks, and entering operationmodesrequire users toinput acontrolle password, preventing unauthorized access and reducing the risk of human error.
Monitoring List Configuration
Services
Full Lifecycle Support and Rapid Response for Optimizing User Experience
With nearly 20 years of experience infunctional safety,we offer comprehensivelifecycle services and suport backed by a specialized R&D team and over 30 TUV-certified engineers. HollySys' technical expertise and professional services ensure a solid foundation for your projects.
Project Services
Ourextensiprjet experiencecmbined witharofsnal amandstreamlindprjt manageent rocese efficientqualtydtidelvrpridfllilervicfrjt itaterata including design, engineering, commissioning,and operations.
Lifecycle Services
OurlifeyeericesoffnratdffcietandlalelutonWminizwtrmauaintna waranties and on-sitemaintenance to spare parts management. Ugrading and miration services ensure your systems sta up-to-date,adapting to fast-evolving technologies.
Training Services
Ourfullyquipd tranngenter staffdbxperiened intrutosoffesand-nstmtrnin tmaxmizeai outomealredtyratioadeprvidestidtraningltobaeddieret prdtsandi participants.
Consulting Services
Withleading-dgeinsightxtesivxperien anadvanced techlgiweheclentslckthealfivat and accelerate theirsustainablecompetitiveadvantageOurconsulting ervicesfousondignsticsandplanningofdigital and smart manufacturing and enginering management guiding buinessesin their ransformation todigital and inteligent operations.
Typical Cases
Cutting-Edge Technology for Safe and Reliabe Production Facilities and Steady Growth
Since its market launch in 2013, HiaGuard SIS has been implemented in over 4,000 projects across a wide range of industries,including refining and petrochemicalscoal chemical,oil and gas,oilandgasstorage and transportation, energy and power, metallurgy, pulp and paper, and food and pharmaceuticals.
Sinopec Tianjin Nan’ gang 1.2 MTA Ethylene & Downstream High-End New Materials Industry Cluster Project (SIS)
Project Background
Sinopec's first large-scale refining and chemical projectfocusing onhigh-end newmaterials. Alarge integrated SIS project used for themegatonethylene mainunitsand akeyresearchprojct inSinpec's milion-ton ethylene engineering, promoting the advancement of critical control systems in major energy sectors.
Solution
The application equipment of the project includes ethylene cracking furnace, cracking steam andoihydrogenationunit, butadiene xtraction units, MTBE/butene- units aromatics extraction units, LLDPEunits,PPunits, AOunits POnit, tank farm units, waste incineratorunits, auxiliary heating boilerunits, solid waste treatment facilities, t. Withve0SISsSIontrol stationsthnetwork architectue featureCRCentralControlmandFi Assemble Rack Room) The system also includes 23 engineering stations, 21 operator stations, and 223 cabinets.
Zhongke (Guangdong) Refinery & Petrochemical Dongxing Branch 5 MTA Oil Refinary Retrofitting Project (SIS)
Project Background
The pre-retrofit systemhadbeenrnning foranextendedperiodwithincomletedocumentationThecustomerrequiredan optimizedcontrololutionwhileconsideringlmitedcabint paceandcablereuseTheretrofithadtobecomletedwithin tight 45-day schedule.
Solution
Theapplicationquipmentf thprjetincldesdieehdrogenationnitontinuusformingunitatmshricd vacumdistilattert#atalttsteetheartsfnstat 2,118 SIS points, as wellas 6 engineering stations, 7 operator stations and 31 cabinets.
CNOoC Shenzhen Branch Enping 15-1 Oilfield Cluster Development Project (ESD+FGS)
ProjectBackground
It isalandmarprjct in'sdigital ranfomationandinteligetilfieldcntrutionandanoffshreoilfed toa intelligent solutions at the designstage.Itis alsothelargestoffshore oilproductionplaforminAsia.
Solution
HollySysisthrmaymatolfiplaminthrtprvidingandwith ThesystemincludesESDandFGScontrolstationsusingadistributedntworkstructureofRCentralControlRoomnd FAR(FieldAssemle Rack Room) and onshore teminalst alsofeatures4enineering stations,10operatorstations,and cabinets.
Sinopec Guangzhou BranchSafety Instrument System Application Project
Project Background
As the petrochemical andchemicalindustryrapidlyadvancestoward atomationand intligence,demandsforprodutio safety andenviromentalprotectionareinreasinglystringentShasbecmeacrucialtechnlogyforensuring afe produti and regulatory compliance.
Solution
The prjet encmpasseitarmaticintemediate takarea,farepolystyrenedstiltonand storagetankre covering ve 10pointsTh system configurationincldes6SIcontrolle19 cabinets,5engineering stations, and operator stations.
Zhong' an United Coal Chemical (ZAUCC) 1.7 MTA Coal to Methanol and Olefin Conversion Project(GDS)
Project Background
It is a flagship project of Sinopec's integrated coal chemical operations.
Solution
HollySys participated in the projct construction inMVmodeThe project ivoles9coal chemical units withver0GDS points. The system is equipped with 12 control stations, 3 engineering stations, and 16 operator stations.
BASF (Guangdong) Integrated Base Project (GDS)
ProjectBackground
Withatotalinvestmentof approximatel1bilioneuros,it isthelargest single investmentbyGemancmpanyinChina The project was launched in November 2019, and its 1st phase includes 10 production clusters, with a focus on a1 MTA ethylene unit and downstream processing units, each developed using EPC models.
Solution
AsaGasettiostmupleyroviddwithernuit2onlr cabinets for the 10 production clusters using HiaGuard SIL3 SIS.
Sinopec-SABIC (Tianjin) Petrochemical 1.3 MTA Ethylene Retrofitting Project (GDS)
ProjectBackground
It is a large-scale application of GDS with large single-unit output cracking furnace.
Solution
he prjct covers ethylenecracking, paratindevice, circulating wate device,tank fam,units,wtemerat loading and unloading station, fire pump station and glycol device and so on. With264GDS points, thesystemincluds4GDScontrol stations inanetwork architcture ofCRCentral ControlRm and FAR(FiedAssembleackoom)h systemalsincle1engineering station,2peratorstations and2cat
Luxi Chemical Group Coal GasificationUnit Upgrading Project (SIS)
Project Background
Thecoal gasificatiouitradngwsamdat ehaninprtioficenypron chicalmatbityad safety,simplifying operation and maintenance processes, and reducing overalloperating costs
Solution
This prject cldscogasificatiounit faewithearlySpointsTesystmconfigurationincen stations,5engineeringstations,and5operatorstations.
Qikou 17-3PlatformCentral Control SystemRetrofittingProject(SIS ^+ FGS)
Project Background
It is anoffshoreplatformcontrolsystemproject initiatedtoreplace the old system.
Solution
The pre-retrofit system,aMitsubishiLC,was inuse from1995to 2014.The prject comleted in2014includes nearly20SIS points and 200 FGS points.
Appendix
Appendix 1:Standardsand Specifications
| Functional safety | IEC 61508 Parts 1-7:2010 |
| IEC 61511 Parts 1-3:2016 | |
| General standards | IEC 61131-2:2017 |
| IEC 61131-6:2012 | |
| Electromagnetic compatibility | IEC 61326-3-1:2017 |
| IEC 61000-6-7:2014 | |
| IEC 61000-6-2:2016 | |
| IEC 61000-6-4:2018 | |
| IEC 61326-1:2012 | |
| IEC 61131-6:2012 | |
| IEC 61000-4-11:2004 | |
| IEC 61000-6-4:2011 | |
| IEC 61000-4:2008 | |
| IEC 61000-4:2004 | |
| IEC 61000-4:2005 | |
| Corrosion prevention ANSI / ISA 71.04-2013 | |
| Application standards | NFPA72:2016 |
| EN54-2:1997/A1:2006 | |
| NFPA85:2015 NFPA86:2015 | |
| EN50156-1:2015 | |
| EN298:2012 | |
| EN50130-4:2011+A1:2014 | |
| Classification Society Certification | GD22-2015 |
Appendix 2: Hardware List
| Products | Model | Clarification |
| QS10 | Power supply module, 24 V DC/10 A | |
| QS20 | Power supply module, 24 V DC/20 A | |
| PRO MAX 240 W 24 V 10 A | Power supply module, 24V DC/10 A | |
| PRO MAX 480 W 24 V 20 A | Power supply module, 24 V DC/20 A | |
| Rack | SGM101 | Main rack |
| SGM110 | Extension rack | |
| Controller | SGM201 | Controller |
| Communication | SGM210 | System communication module |
| SGM220 | Remote I/0 communication module (multi-mode optical fiber) | |
| SGM221 | Remote I/0 communication module (three-port single-mode optical fiber) | |
| SGM222 | Remote I/O communication module (single-port single-mode optical fiber) | |
| SGM230 | Modbus communication module | |
| SGM240 | I/0 communication repeater module | |
| 1/0 module | SGM410 | 16-channel analog input module |
| SGM410H | 16-channel analog input module with HART | |
| SGM412H | 32-channel analog input module with HART | |
| SGM520 | 8-channel analog output module | |
| SGM520H | 8-channel analog output module with HART | |
| SGM610 | 32-channel digital input module | |
| SGM610S | 32-channel full diagnostic digital input module | |
| SGM710 SGM633 | 32-channel digital output module | |
| SGM3410 | 32-channel switch input module 16-channel analog input terminal module | |
| SGM3410H | ||
| 16-channel analog input terminal module with HART | ||
| SGM3412H | 32-channel analog input terminal module with HART | |
| SGM3520 | 8-channel analog output terminal module with HART | |
| SGM3610 | 32-channel digital input terminal module | |
| SGM3610S | 32-channel full diagnostic digital input terminal module | |
| SGM3620 | 32-channel digital input relay terminal module (non-safety) | |
| SGM3710 | 32-channel digital output terminal module | |
| SGM3720 | 32-channel digital output relay terminal module(non-safety) | |
| SGM3633 | Pulse input and overspeed protection terminal module I0 Bus communication extension cable of 2 m, 4 m, 5 m, 10 m, and 15 m to | |
| SGX002 | connect tworacks 78-core pre-fabricated cable of 1.5 m, 2 m, 4 m, 6 m, 10 m, 16 m to connect | |
| SGX006-SGX011 | racks and terminal modules | |
| Fault detection | SGX012 | Modbus module communication extension cable of 3 m External cable fault detectionmodule(used with SGM610 module) |
| SGM8610 | External cable fault detection module (used with SGM610 module) | |
| module Placeholder | SGM8611 SGM020 | Empty slot placeholder panel within the rack |
| SGM021 | Empty slot placeholder module within the rack (European insert corrosion- |
Key Accounts
For further inquiries
sales_international@hollysys.com
For more information
www.hollysys.com
Singapore
Changi Business Park Crescent, #04- 01/02/03 Plaza 8 {0} CBP,Tower A,Singapore 486025
China No.2 Di Sheng Middle Road, Economic-Technological Development Area,Beijing 100176
India D-84, Ground Floor, Sector63,Noida,Uttar Pradesh 201301
Indonesia Metropolitan Tower, 10th Floor Unit E JI. R.A. Kartini Kav. 14, Jakarta 12430
Uzbekistan
10, Mahmoud Tarabi Street,Tashkent,Uzbekistan
