Model-based Safety Assessment of Industrial Automation Systems Using IEC 61499

Model-based Safety Assessment of Industrial Automation Systems Using IEC 61499
Author: Zeeshan Ejaz Bhatti
Publisher:
Total Pages: 219
Release: 2017
Genre: Model-driven software architecture
ISBN:

Industrial automation systems are complex control systems that perform control and automation of hazardous plants. Safety of such systems is of paramount importance and may even be mandated by law. Safety-related systems may be required to demonstrate conformance to an applicable functional safety standards to assure safety and demonstrate the that these systems mitigate the risk to human lives, as much as reasonably possible. IEC 61508 is a standard of functional safety for generic electric, electronic, and programmable electronic (E/E/PE) systems and is used as the principal guide in this thesis. IEC 61508 adopts a two-pronged approach for addressing random failures in the hardware and systematic errors in the software. Random failures are addressed using quantitative techniques for reliability analysis e.g., reliability block diagrams and Markov analysis, and by computing the safe failure fraction to establish a confidence level. Systematic errors, on the other hand, are avoided by following quality assurance recommendations and qualitative validation techniques. However, this segregated application of quantitative and qualitative approaches is inadequate for addressing complexities introduced by software-intensive control systems. Furthermore, the manual application of traditional safety analysis techniques is tedious, error-prone, and largely dependent on practitioners' skills. In order to ameliorate these problems, a model-driven approach towards safety analysis named, model-based safety assessment (MBSA) was proposed, which has gained significant interest in academia and industry in the recent years. MBSA approaches use system models for the purpose of safety analysis such as extracting fault trees, performing quantitative analysis, or discovering a critical sequence of errors that may cause system failures. MBSA can be performed on either by using dedicated safety models or by using system development models. The latter approach allows seamless integration with model-driven development (MDD), which is the state-of-the-art for design, implementation and validation of control and automation systems. In MDD, high-level system models are constructed that are iteratively refined by adding details until an implementation of the system software can be automatically extracted from the development models using automatic code generation. One such approach for implementing industrial control systems uses IEC 61499, which is an open standard for implementing industrial process controller and measurement systems. It proposes various design artefacts e.g., basic and composite function blocks and enables a component-oriented design approach for implementing complex behaviours i.e., by connecting function blocks to form function block networks. A popular design pattern for the development of IEC 61499 based systems suggests the implementation of two separate tiers called plant-model and controller. The plantmodel mimics the expected behaviour of the plant and the controller implements the automation logic. When connected in a closed-loop, the overall system model is formed that is used for various verification and validation activities such as formal verification, testing, simulation. Such analyses are well-suited for safety-critical systems and help to avoid systematic errors. However, plant-models are also susceptible to random errors, which cannot be analysed by using qualitative techniques alone. Unfortunately, all existing validation and verification techniques available for IEC 61499 based systems are qualitative in nature, which cannot be used for the purpose of quantitative risk assessment. This calls for developing an approach for the quantitative safety assessment of IEC 61499 based systems. In this thesis, we present an MBSA approach for quantitative risk assessment of industrial automation systems using IEC 61499. The presented approach proposes a novel structure named stochastic function block for modelling stochastic aspects of random failures and environmental non-determinism in the plant-model. The controller, on the other hand, is developed using standard IEC 61499 function blocks. The overall system model is transformed into Markov decision processes in the Prism language for probabilistic verification using the Prism model checker. This enables quantitative analysis of the system behaviour presuming software behaviour under random errors of the plant. The controller is eventually used for automatic code generation and deployment onto the physical plant. Use of standard function blocks for the controller renders the proposed technique complaint to the IEC 61499 standard and permit seamless integration into the MDD activities. The key contributions of the presented work are as following. 1) A novel structure based on IEC 61499 basic function blocks named stochastic function block. This structure is used for representing the random errors in the plant model and environmental non-determinism. 2) A rule-based transformation from IEC 61499 function blocks to Prism model that preserves the adopted synchronous execution semantics. The generated Prism model is a Markov decision process that represents the probabilistic and non-deterministic aspects of the system due to its random errors. 3) A scalable MBSA approach for a unified qualitative and quantitative analysis, which is useful in the early design validation and managing modifications in system design. 4) An MDE tool-chain named BlokIDE, which provides support for the proposed stochastic function blocks and automatic translation to the Prism language. This enables stochastic error modelling and integration with the Prism model checker for the purpose of proposed MBSA approach. 5) A proposal for conforming to IEC 61508 requirements using IEC 61499 modelbased approach, showing various specification and design various stages of the V-Model. To the best of our knowledge, the proposed approach is the very first attempt for providing a model-based safety assessment approach for industrial automation systems using IEC 61499 along with a comprehensive tool-chain.

Predictive Safety Analytics

Predictive Safety Analytics
Author: Robert Stevens
Publisher: CRC Press
Total Pages: 99
Release: 2023-10-03
Genre: Computers
ISBN: 1003806244

Nearly all our safety data collection and reporting systems are backwardlooking: incident reports; dashboards; compliance monitoring systems; and so on. This book shows how we can use safety data in a forward-looking, predictive sense. Predictive Safety Analytics: Reducing Risk through Modeling and Machine Learning contains real use cases where organizations have reduced incidents by employing predictive analytics to foresee and mitigate future risks. It discusses how Predictive Safety Analytics is an opportunity to break through the plateau problem where safety rate improvements have stagnated in many organizations. The book presents how the use of data, coupled with advanced analytical techniques, including machine learning, has become a proven and successful innovation. Emphasis is placed on how the book can “meet you where you are” by illuminating a path to get there, starting with simple data the organization likely already has. Highlights of the book are the real examples and case studies that will assist in generating thoughts and ideas for what might work for individual readers and how they can adapt the information to their particular situations. This book is written for professionals and researchers in system reliability, risk and safety assessment, quality control, operational managers in selected industries, data scientists, and ML engineers. Students taking courses in these areas will also find this book of interest to them.

Industrial Automation Technologies

Industrial Automation Technologies
Author: Chanchal Dey
Publisher: CRC Press
Total Pages: 329
Release: 2020-05-28
Genre: Technology & Engineering
ISBN: 1000068781

The book begins with an overview of automation history and followed by chapters on PLC, DCS, and SCADA –describing how such technologies have become synonymous in process instrumentation and control. The book then introduces the niche of Fieldbuses in process industries. It then goes on to discuss wireless communication in the automation sector and its applications in the industrial arena. The book also discusses theall-pervading IoT and its industrial cousin,IIoT, which is finding increasing applications in process automation and control domain. The last chapter introduces OPC technology which has strongly emerged as a defacto standard for interoperable data exchange between multi-vendor software applications and bridges the divide between heterogeneous automation worlds in a very effective way. Key features: Presents an overall industrial automation scenario as it evolved over the years Discusses the already established PLC, DCS, and SCADA in a thorough and lucid manner and their recent advancements Provides an insight into today’s industrial automation field Reviews Fieldbus communication and WSNs in the context of industrial communication Explores IIoT in process automation and control fields Introduces OPC which has already carved out a niche among industrial communication technologies with its seamless connectivity in a heterogeneous automation world Dr. Chanchal Dey is Associate Professor in the Department of Applied Physics, Instrumentation Engineering Section, University of Calcutta. He is a reviewer of IEEE, Elsevier, Springer, Acta Press, Sage, and Taylor & Francis Publishers. He has more than 80 papers in international journals and conference publications. His research interests include intelligent process control using conventional, fuzzy, and neuro-fuzzy techniques. Dr. Sunit Kumar Sen is an ex-professor, Department of Applied Physics, Instrumentation Engineering Section, University of Calcutta. He was a coordinator of two projects sponsored by AICTE and UGC, Government of India. He has published around70 papers in international and national journals and conferences and has published three books – the last one was published by CRC Press in 2014. He is a reviewer of Measurement, Elsevier. His field of interest is new designs of ADCs and DACs.

Safety Differently

Safety Differently
Author: Sidney Dekker
Publisher: CRC Press
Total Pages: 316
Release: 2014-06-23
Genre: Technology & Engineering
ISBN: 1482241994

The second edition of a bestseller, Safety Differently: Human Factors for a New Era is a complete update of Ten Questions About Human Error: A New View of Human Factors and System Safety. Today, the unrelenting pace of technology change and growth of complexity calls for a different kind of safety thinking. Automation and new technologies have resulted in new roles, decisions, and vulnerabilities whilst practitioners are also faced with new levels of complexity, adaptation, and constraints. It is becoming increasingly apparent that conventional approaches to safety and human factors are not equipped to cope with these challenges and that a new era in safety is necessary. In addition to new material covering changes in the field during the past decade, the book takes a new approach to discussing safety. The previous edition looked critically at the answers human factors would typically provide and compared/contrasted them with current research and insights at that time. The edition explains how to turn safety from a bureaucratic accountability back into an ethical responsibility for those who do our dangerous work, and how to embrace the human factor not as a problem to control, but as a solution to harness. See What’s in the New Edition: New approach reflects changes in the field Updated coverage of system safety and technology changes Latest human factors/ergonomics research applicable to safety Organizations, companies, and industries are faced with new demands and pressures resulting from the dynamics and nature of the modern marketplace and from the development and introduction of new technologies. This new era calls for a different kind of safety thinking, a thinking that sees people as the source of diversity, insight, creativity, and wisdom about safety, not as the source of risk that undermines an otherwise safe system. It calls for a kind of thinking that is quicker to trust people and mistrust bureaucracy, and that is more committed to actually preventing harm than to looking good. This book takes a forward-looking and assertively progressive view that prepares you to resolve current safety issues in any field.

Model-Based Safety Analysis

Model-Based Safety Analysis
Author: National Aeronautics and Space Administration (NASA)
Publisher: Createspace Independent Publishing Platform
Total Pages: 60
Release: 2018-06-03
Genre:
ISBN: 9781720627142

System safety analysis techniques are well established and are used extensively during the design of safety-critical systems. Despite this, most of the techniques are highly subjective and dependent on the skill of the practitioner. Since these analyses are usually based on an informal system model, it is unlikely that they will be complete, consistent, and error free. In fact, the lack of precise models of the system architecture and its failure modes often forces the safety analysts to devote much of their effort to gathering architectural details about the system behavior from several sources and embedding this information in the safety artifacts such as the fault trees. This report describes Model-Based Safety Analysis, an approach in which the system and safety engineers share a common system model created using a model-based development process. By extending the system model with a fault model as well as relevant portions of the physical system to be controlled, automated support can be provided for much of the safety analysis. We believe that by using a common model for both system and safety engineering and automating parts of the safety analysis, we can both reduce the cost and improve the quality of the safety analysis. Here we present our vision of model-based safety analysis and discuss the advantages and challenges in making this approach practical.Joshi, Anjali and Heimdahl, Mats P. E. and Miller, Steven P. and Whalen, Mike W.Langley Research CenterSYSTEMS ENGINEERING; MODELS; FORMALISM; SAFETY; AUTOMATIC CONTROL; COST REDUCTION; FAILURE MODES; FAULT TREES; DIGITAL SYSTEMS

Industrial Process Automation Systems

Industrial Process Automation Systems
Author: B.R. Mehta
Publisher: Butterworth-Heinemann
Total Pages: 668
Release: 2014-11-26
Genre: Technology & Engineering
ISBN: 0128010983

Industrial Process Automation Systems: Design and Implementation is a clear guide to the practicalities of modern industrial automation systems. Bridging the gap between theory and technician-level coverage, it offers a pragmatic approach to the subject based on industrial experience, taking in the latest technologies and professional practices.Its comprehensive coverage of concepts and applications provides engineers with the knowledge they need before referring to vendor documentation, while clear guidelines for implementing process control options and worked examples of deployments translate theory into practice with ease.This book is an ideal introduction to the subject for junior level professionals as well as being an essential reference for more experienced practitioners. Provides knowledge of the different systems available and their applications, enabling engineers to design automation solutions to solve real industry problems Includes case studies and practical information on key items that need to be considered when procuring automation systems Written by an experienced practitioner from a leading technology company

Safety, Reliability and Risk Analysis

Safety, Reliability and Risk Analysis
Author: Sebastian Martorell
Publisher: CRC Press
Total Pages: 3512
Release: 2008-09-10
Genre: Technology & Engineering
ISBN: 1482266482

Safety, Reliability and Risk Analysis. Theory, Methods and Applications contains the papers presented at the joint ESREL (European Safety and Reliability) and SRA-Europe (Society for Risk Analysis Europe) Conference (Valencia, Spain, 22-25 September 2008). The book covers a wide range of topics, including: Accident and Incident Investigation; Crisi

Control Systems, Robotics and AutomatioN – Volume XVI

Control Systems, Robotics and AutomatioN – Volume XVI
Author: Heinz D. Unbehauen
Publisher: EOLSS Publications
Total Pages: 524
Release: 2009-10-11
Genre:
ISBN: 1848261551

This Encyclopedia of Control Systems, Robotics, and Automation is a component of the global Encyclopedia of Life Support Systems EOLSS, which is an integrated compendium of twenty one Encyclopedias. This 22-volume set contains 240 chapters, each of size 5000-30000 words, with perspectives, applications and extensive illustrations. It is the only publication of its kind carrying state-of-the-art knowledge in the fields of Control Systems, Robotics, and Automation and is aimed, by virtue of the several applications, at the following five major target audiences: University and College Students, Educators, Professional Practitioners, Research Personnel and Policy Analysts, Managers, and Decision Makers and NGOs.

Trends in Advanced Intelligent Control, Optimization and Automation

Trends in Advanced Intelligent Control, Optimization and Automation
Author: Wojciech Mitkowski
Publisher: Springer
Total Pages: 886
Release: 2017-06-06
Genre: Technology & Engineering
ISBN: 3319606999

This volume contains the proceedings of the KKA 2017 – the 19th Polish Control Conference, organized by the Department of Automatics and Biomedical Engineering, AGH University of Science and Technology in Kraków, Poland on June 18–21, 2017, under the auspices of the Committee on Automatic Control and Robotics of the Polish Academy of Sciences, and the Commission for Engineering Sciences of the Polish Academy of Arts and Sciences. Part 1 deals with general issues of modeling and control, notably flow modeling and control, sliding mode, predictive, dual, etc. control. In turn, Part 2 focuses on optimization, estimation and prediction for control. Part 3 is concerned with autonomous vehicles, while Part 4 addresses applications. Part 5 discusses computer methods in control, and Part 6 examines fractional order calculus in the modeling and control of dynamic systems. Part 7 focuses on modern robotics. Part 8 deals with modeling and identification, while Part 9 deals with problems related to security, fault detection and diagnostics. Part 10 explores intelligent systems in automatic control, and Part 11 discusses the use of control tools and techniques in biomedical engineering. Lastly, Part 12 considers engineering education and teaching with regard to automatic control and robotics.