Integrated Protective Solutions FGS AND SAFETY Bob Lee, … · 2015-09-15 · Third Party Interface Solutions Number vendors Same single vendor >= 2 vendors Spec, project schedule

2015 Japan Technology Summit

Yokohama, September 9-10

Integrated Protective Solutions – FGS AND SAFETY

Bob Lee, Integrated Protective Solutions, AP leader

2 © 2014 Honeywell International All Rights Reserved2 © 2015 Honeywell International All Rights Reserved

Level controller not design for >10feet high. At 10am

filled >20times than allowed yet controller indicated

<10feet. At 12pm, high pressure alarm activated.

Operator manual the valve for release

Flow to

blowdown valve

and waste sewer

Functional Safety definition

Safety is prevention against abnormality

hazards, while

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../SIS services.pptx


Fire & Gas detection and mitigation definition

Fire and Gas Detection

An explosion caused by

a gas leak in the

southern Taiwanese city

Kaohsiung has killed 15

people and injured

another 243

Fire & Gas detection is early mitigation against

further loss,

Safety is prevention against abnormality hazards, while

../../Work video/work accident video/Mexico_Pemex19Sep2012 - Gas explosion.mp4

../../Work video/work accident video/Mexico_Pemex19Sep2012 - Gas explosion.mp4


Fire, Safety and Security >> Safety Inter–related

Fire & Gas detection is early mitigation against further loss,

Security is protection against intentional intrusion/damage

Safety is prevention against abnormality hazards, while

Fire, Safety and Security are interlinked to further risk reduction


Fire and Gas Solutions

Experion HMI

DCS+Building

PSD/ESD/BMS..

Partial Valve Stroke

Testing

TUV Certified Safety

Engineers

Safety SIS Fire and Gas/Security/One–Wireless

Flame & Gas Detection & Mapping

Camera, RADAR,

PIDS and ACS

Solutions

SIL/FGS Study

Fire Alarm Solutions

One–Wireless Solutions

Industrial Security Solutions

portable gas

detector

Fixed Flame/gas

detector

Field InstrLocation

finder

Wireless –

ISA100,

IEEE802–

WIFI and

RSSI

location

Fire & HSSD cabinet

Detection

Honeywell Integrated Protective Solutions


Integrated Fire&Gas, Safety and Security in action – Demo…


Why Integrated Protective Soln is more efficient

and better

Functions One–Honeywell IPS soln Third Party Interface Solutions

Number vendors Same single vendor >= 2 vendors

Integration (EPKS, EIS..) Publish & Share (DSA) Add, modify and delete (OPC/MB)

Engrg Configuration Seamless, no effort Need to build dummy pts/map

Alarm, and Card access,

CCTV Management

Share alarm group.

Suppress and shelvingNeed manual and tedious engrg soln

Network firewall

(Cyber Security issue)Pass thru seamlessly

Need to open port and may not able

to pass thru Firewall

HMI and global data access SeamlessNeed to build HMI at DCS and

tedious engrg

Ease of last minute/future

additional and modification

manual engrg

No disruption to current sys

(Pub/share via DSA)Need manual engrg on 3 parties

One–Wireless industrial

solutions

Integrated wireless for field

instrument, security and gas

detection

Industrial Wireless mainly limited to

DCS field instrument

Software upgrade seamless Need at least 2 vendors involvement


Case study on Fire Safety projects – Generic

architecture

Heat Detector

Fire

Alarm

System

ESD System

Smoke Detector

Flame Detector

Manual Call Point

Audible/Visual AlarmFlame/Gas

Detector

Process

Function

Building

Function

Fire & Gas

System

DCS

System

Using Fire Alarm System

• Model: XLS3000

• Manufactured in: USA

• IO/Detector Com. Type:

Intelligent Addressable

• Origin Code: NFPA

• Certification: UL/FM

• L2 Sequence: Cross zone

Using F&G System

• Model: Safety Manager

• Manufactured in: Netherland

• IO/Detector Com Type:

Conventional non addressable

• Origin Code: IEC

• Certification: SIL3

TUV/EN/NFPA / FM

• L2 Sequence: 2ooNAnd/

or


CPU

PWR +

ChargerBAT

loop

loop

Signal Line Circuit

Notification Device

Circuit

MB

GW

N S/W N S/W

P. Net.

Patch Panel

MB

GW

Case Study – FAP standard communication


Process 1

Admin

Main CCR

Fire Station

Substation 2 Substation 1

Fire StationSubstation 3 WarehouseGuard House

Canteen

Clinic

Process 2

Operation Shelter

Case Study – FGS and Safety System StructureCase Study – Standalone FAP System Structure


Reference sites – Shaybah, BS–132, Manifa…

EPCs:

• Samsung

• SKEC

• JGC

• Technicas

• Hyundai

Case Study 1 – Simple Ring network FAP System

Structure


Reference sites – WQ2, JAC, JRC, TG, JGSummit,

SABIC….

Case Study 2 – One–Ring network FAP System

Structure

EPCs:

• Samsung

• SKEC

• Hyundai

• Toyo

• Essar


Process 1

Admin

Main CCR

Fire Station

Substation 2 Substation 1

Fire StationSubstation 3 WarehouseGuard House

Canteen

Clinic

ICSS LFACP

GraphicProcess 2

Operation Shelter

Case Study 3 – FGS and Safety Multi–fault

System Structure

Proprietary integration or Modbus

Safety Manager network

FAP–SM multi fault tolerant network

EPCs:

• Hanwha

• AMEC FW

• JGC

• Flour

• Petrofac

• Saipem

• Hyundai

• Technicas


MAA

Refinery

SHU

Refinery

MAB

Refinery

50,000 Detectors/devices

187 XLS3000

177 XLS140

60 SM

8 EPKS

Server

Case Study – FGS and Safety Multi–fault – Kuwait FGS

Halon and Safety solution replacement Project


Complex FGS and Safety design – existing multi–vendors

and multi fault tolerant communication

Ethernet Ring for

Modbus TCP

XLS Ring

NCA2 x 2

Modbus RTU

For total XLS

Net

Ethernet Ring

for Modbus TCP

…… N x units of

XLS Panel

Modbus TCP in furthest

point of XLS Ring from

control room

Control Room


Ethernet Ring for

Modbus TCP

XLS Ring

NCA2 x 2

Modbus RTU

For total XLS Net

Ethernet Ring for

Modbus TCP

…… N x units of

XLS Panel

Modbus TCP in furthest

point of XLS Ring from

control room

ONE FaultTWO Fault

THREE FaultFOUR Fault

FIVE Fault

2x FO Ring: ONE Fault tolerant for Ethernet Ring, TWO

Fault tolerant for XLS–Net

Control Room

Complex FGS and Safety design – existing multi–vendors

and multi fault tolerant communication


• 18 Monitoring Location (ECCC, CCR)

• 2 Supervisory Server

• 24 MFAP Cluster

• 170 SFAP/GSP

Case Study – FGS and Safety Multi–fault –

MAA architecture


Existing ExistingExtension

(50 Buildings)

• 18 EPKS Station

• 2 EPKS Server

• 24 SM

• 170 XLS

• 9 EPKS Station

• 1 EPKS Server

• 6 SM

• 61 XLS

DSA DSA


MAA extension


Extension

(90 buildings)

• 4 EPKS Station

• 3 EPKS Server

• 21 SM

• 123 XLS

• 3 EPKS Station

• 1 EPKS Server

• 11 SM

• 128 XLS

DSA DSA


MAB extension



more to come…


• Maintain Design Consistency ‒ One industrial compliance project execution plan include

methodology, documentation, design concept and approval

requirement

‒ One–team project plan – One–PM, One-Lead excellence, One-

Quality control, One-COE product/soln support

‒ At EPC & Endususer location and site services support

• One-Manufacturing location ‒ Maintain Quality Standard/Consistency for all EPCs

Kuwait Project Execution Model (FGS and Safety)


Project Organization and Execution Model

(FGS and Safety)

Customer expects One–location, one project execution plan


Why/how Honeywell can meet EPC and Enduser

expectations

FunctionsOne–Honeywell FGS Safety

solutionThird Party Interface Solutions

Number vendors Same single vendor >= 2 vendors

Spec, project schedule and risk

compliance

Fully compliance with proven

mega projects (KNPC,

Aramco, EPCs..)

Difficult due to incomplete

product/solutions, global presence and

heavily dependent on 3rd party handling

Ease of last minute/future

additional and modification

manual engrg

No disruption to current sys

(One–team, Pub/share via

DSA)

Need multi vendors and manual engrg on

3 parties

Integration (SM and EPKS,

detectors..)

Special protocol, Publish &

Share (DSA),Add, modify and delete (OPC/MB)

Engineering ConfigurationIn–house development,

almost Seamless, no effortNeed to build dummy pts/map

Alarm, and HMI ManagementShare alarm group. Suppress

and shelvingNeed manual and tedious engrg soln

Network firewall

(Cyber Security issue)Pass thru seamlessly

Need to open port and may not able to

pass thru Firewall

Software upgrade Seamless – One stop shop Multi–vendors concern on compatibility


Thank you!

Any

Questions?


Thank you!

Any

Questions?

Supplements slides

on

Honeywell product and solutions capability


Honeywell Flame and Gas Detection Offerings What is he doing???

../../../Users/E158804/Desktop/KNPC/Honeywell overall gas detection.pdf


Alarm Manager & FDM relevance for Flame and

Gas detection

OneWireless

HART Adaptor

Wireless Device Manager

Universal Safety

I/O

Universal Safety

Logic Solver

Safety Manager

ExperionServer

Alarm Manager Server

Experion Stationwith AM Client

Alarm Manager

Client

Field Device

Manager Server

FDM Client

Experion Stationwith FDM Client

One Wireless key Customers –Marathon, Shell, BP, TOTAL, SHAH Gas

http://www.detect-measure.com/manuf_zell.html

http://www.detect-measure.com/manuf_zell.html


STAGE 4STAGE 1 STAGE 2 STAGE 3

VISIBLE SMOKE INTENSE HEATFLAMING FIREINCIPIENT STAGE – NO VISIBLE SMOKE

TIME

SM

OK

E D

EN

SIT

Y A

ND

HE

AT

OU

TP

UT

Fire stages – Detectors

HSSD

Point type

HSSD

Aspiration type

What is the earliest method of Fire detection


HSSD smoke detector – Point type vs Aspirator

Addressable Fire detectors,Modules, Manual Call Points

Honeywell Compliance

Solution:

Point addressable HSSD

detectorSLC loop 1

SLC loop 2

Non–addressable

Air sampling type

Interface moduleLFAP

Honeywell XLS3000

LFAP

@ 1–10 Addressable Loops (3180 devices)

@ 200 nodes Fire Network XLS–Net

@ UL/FM/PSB certified

Stage 1 Fire

Addressable

Video/Intro_FAAST_MedFormat_HiRes.mp4

Video/Intro_FAAST_MedFormat_HiRes.mp4


Fire stages – Detectors

STAGE 4STAGE 1 STAGE 2 STAGE 3

VISIBLE SMOKE INTENSE HEATFLAMING FIREINCIPIENT STAGE – NO VISIBLE SMOKE

TIME

SM

OK

E D

EN

SIT

Y A

ND

HE

AT

OU

TP

UT

PHOTO

ION

BEAM

SPRINKLER

HEAT

HSSD

Point type

HSSD

Aspiration typeFLAME


Honeywell Industrial Fire Alarm panel Product Range

– XLS3000/140/120 and Safety Manager

Intelligent

Field Devices

Honeywell Product Line

Item

s p

er

Lin

e

Signal

Notification

Automatic Fire

Safety System

Voice

Evacuation

Graphic

User

Interface

System

Integration

or interface

Acclimate Detector

Pinnacle HSSD Detector

HARSH Detector

Beam Detector

I/O Modules

Manual Call Point

LED Annunciator

Repeater Panel

Remote Display

Mimic Display

XLS140

DVC/Variody D1 PAVA

Digital Audio Amplifier

Speaker

Remote Monitoring

Experion Integrated

HMI

Modbus/BACnet Interface

Third–party Integrator

NION Interface

Very Early Warning Smoke detector

XLS120

XLS3000

PAGA – FGS integrationSafety Manager

NCM and FNA


Generic XLS3000 Fire alarm configuration

overview

Primary (AC)

Secondary (DC)

Custom Graphic

Annunciator

Monitoring

XLS–NET (200 nodes)

SLC connect upto 159 detectors and 159 IO modules

XLS3000 has max

10 SLC loops

XLS3000 has

max 10 SLC

loops

NCA Master panel

Fire Gate

ValveFire

Suppres

sion

system

FGS and DCS systems

Building facilities

and voice system


Honeywell Fire Systems Offerings

Fire Panels

Electronic “addressable” Detectors

Loop reliability

Industry leading networking capability

over wire or media

UL, GOST, PSBfibre , BOMBA, ACTIV–

FIRE approvals/Marine approved

Panels

Aspirated Smoke Detection

(ASD).. Hon FAAST or VESDA

samples air and analyses for

smoke particles.

`

Building Occupant Warning System

(BOWS)

Or Public Address/General

Announcement (PA/GA) provide sound

reinforcement, voice messages, alert

and evacuation tones to aid rapid and

orderly mobilization of people in an

emergency situation.

Suppression Agent Release modules

within an FACP to control discharge of

extinguishing agent

FlexES – Redundant

CPU FAP

XLS3000 – Standard FAP

HS81 – SIL2 Redundant FAP

Emergency Warning

Devices

Horns, strobes, beacons &

combination units IS/ ExD

rated

Safety Manager

– SIL3, Redundant


- Up to 400 DOMs

- 1,600 DCS/UIMs

- 1,600 Amplifier channels

- 9,600 Loudspeaker lines

Intercom feature between

control rooms

Configuration

Variodyn D1 PA & GA TCP/IP – LAN Network

Configuration via IP

Communication

System

Interface with VOIP Or

Analogue Telephony

Alarm

System

Fire Alarm Or

FGS system

3th party

PA Systems

DAL

DCS15

DCS15

DAL

GUI display

LAN

TCP–IP


Functions Honeywell Others

Wholly owned FGS controller,

Fire alarm panel and PAGA

system

PES/FAP/ PAGA

Example:

SM/XLS3000/Variody

At least one or than 3rd party vendors

Wholly owned Fire, Flame, Gas,

VOC, early smoke fixed

detectors include portable gas

detectors

Sieger/FireSentry/BW/RAE

brands of detectorAt least one or than 3rd party vendors

One–wireless FGS capabilityRAE/Sieger, fixed and

portable wireless networkAt least one or than 3rd party vendors

FGS Alarm and CCTV

integration ManagementExperion/DVM OPC, Third party

In–house, global support and

Industrial compliance project

execution capability

TUV FSM, FGS certified

engineers. Include FGS 3–D

mapping consultant

Partner with third party

World largest FGS solution

project referencesKNPC, Aramco, ShahGas No… partner with 3rd party

FGS mapping software

capabilityGCV 3–D FGS mapping 3rd party and not 3–D

Why Honeywell FGS solution is better


RELAY

PLC’SVOTING

DIAGNOSTICS

2oo2

1oo2 2oo3

1oo11oo1D/1oo2D 2oo3D

2oo4D

Latest Technology

Pneumatic

Relay

Solid State Microprocessor

Smart Diagnostic

Voting

Pneumat

ic

Smart controller– Reliable and

Available

199419891983 2003 2006 20081960s 2013

1950 1960 1980 1988 1998 2005 2012

Technologies applied during the last 80 years


Why Universal Channel Technology is better?

• Extreme temperature range–40 to +70 degrees C, –40 to +158 degrees F

• Embedded field power 24 V dc

• SIL 1 to 3

• Environment classification‒ Class 1 Division 2,

‒ IEC–Ex, ATEX Zone 2

Reactor

PT

1A

PT

1B

AI

FT

AI

DO

DO

AO

DI

USIO application example

AO

–P

VS

T

DI–

LM

Truly soft programmable

IO type…


Remote or local USIO design concept


Seamless integration in overall Experion

• Common database

• Common A&E and HMI

• SM system status and diagnostic at Experion

• Safety access – prevented

• CDA or PCDI peer to peer

CDA integration provides:

• Peer–to–peer communication

• Data access

• Alarms and Events

• Notifications

• Console station support

Both cases, No additional license $$

Honeywell ICSS integrated solutions comply with

IEC61508/61511


Functions DSA and CDA (Honeywell) Others

Logic Solver QMR – 2oo4D DMR/TMR – 1oo2D or 2oo3D

DCS server Integration and

controller peer to peer

Single database, Publish &

ShareModbus, OPC or additional s/w$

Alarm and CCTV integration

ManagementDVM OPC, Third party

Offline proof test interval TUV letter – not require Require, 5 To 10 years

Universal Safety IO – SIL3, soft

programmable IO channel and

fully redundant

Yes No

Intelligent Remote IO capability

– SIL3 USLSYes No

On–line Software upgrade, add

IO rackYes No

FGS Consultancy capability Yes, include 3–D mapping No

Why Honeywell Safety Manager is better


Bob Lee is the Safety Consulting leader for Asia Pacific

Honeywell Process Solutions IPS team to provide consulting

services to help Honeywell clients develop safety solutions

that comply with the IEC61508 and IEC61511 standards.

Bob supports all phases of the safety lifecycle, from Sales

support to project delivery stages. Bob also consults

extensively on other layer of protection solutions like fire and

gas detection/protection and Industrial Security requirement.

Bob has been involved in Process Functional Safety and Fire

& Gas safety engineering projects since 1984 and a Certified

Functional Safety Expert (Y2002 CFSE), Manufacturing

Management Specialist, and Professional Marketer (Asia

Pacific).

Present profile

Bob Lee

Safety Consulting leader

Asia Pacific


Thank you!

Any

Questions?

Documents

Integrated Protective Solutions FGS AND SAFETY Bob Lee, … · 2015-09-15 · Third Party Interface Solutions Number vendors Same single vendor >= 2 vendors Spec, project schedule