2013 Honeywell Users Group Asia Pacific

1

Versatility with Fire & Gas Solutions

Ajay Varghese

2

Safety challenges abound in the industry

Gas Plant EXPLOSION

1000+ Fire & Gas safety incidents – just 9 months of 2012!

3

Detect at an early stage of abnormality the presence of flammable/toxic gases leakage and fire that can lead to explosion & health hazards

Initiate early signal, both audible & visible as required, to warn of the detected hazards

and ensure executive actions… Fire protection/suppression, Emergency Shutdown (ESD) System are deployed consistently through Controller Integrity and availability

The need

Reliable, real time, single window interface for control and safety

• Alert process operators & Fire response to take timely actions to mitigate Fire, Gas leaks and damage

• Alert response personnel for evacutions during Fires and Gas leaks.

Need all round 24 x 7 situational awareness

4

Honeywell Fire & Gas Solutions Approx. $4B F&G product revenue 12,500 Employees

Fire Alarm & Suppression

Systems

Gas & Flame Detection Systems

Sensors and Actuating Devices

Safety Products

Safety PLC & Experion System

• Safety Manager – SIL3 PLC for fire & gas • Experion supervisory system • FAAST & Pinnacle - HSSD system • PA/VA/MNS and voice systems.

UL EN AS NZ

F&G Safety PLC

• XLS range - Addressable fire alarm panels • Gas, Flame, Fire and smoke detection • DVM – Integrated CCTV system • Personal protective equipment

Globally delivering Fire & Gas safety across industries

5

Fault-Tolerant Ethernet

SafeNet

Video Wall

F&G Logic Solver Safety Manager (SIL 3)

Battery Backup

DCS

Fire & Gas detectors, Manual Call Points Sounders, Beacons F&G Mimic Panel

XLS-NET

Life Safety System – Manned Buildings

F&G Mimic Panel

F&G Operator Station

DCS/ESD Operator Station

Addressable Fire detectors, Modules, Manual Call Points

Serial Interface

Honeywell Digital Video

Server

IP Cameras

ESD Safety

Manager

Experion

FGS- Process Unit Areas, E-House, FAS,etc

Addressable Fire Alarm Panel

Safety Manager – Common Platform for F&G and ESD Seamless Data Ex-change through SafeNet (SIL 3)

• FTAs support straight forward connection of supported F&G devices. • Standard function blocks include specific F&G field device set points. • MVIP test program for all supported F&G field devices.

Integration of FGS and Life Safety System Plant Surveillance through CCTV Access control/ Mustering/ Security

One Honeywell Integrated Fire & Gas Solution

Integration with Experion System provides single window view : • System & Field Diagnostics • Alarm Visualization • Event Status, Historian • CCTV Integration

Experion Industrial Security

Leveraging OneWireless infrastructure

6

What do our users say?

We can view detector level information – be it combustible

gas leakage or a fire in a building. It’s a Regulatory

compliant, fully integrated & automated system to provide

us information we need to pro-actively mitigate or suppress

fire with minimal losses.

Fire Operators Plant Operators

From the CCR, we are able to take proactive decisions to ensure safe production and

minimize losses quickly when safety incidents happen. We can monitor through CCTV

systems exactly where & what is happening when a Fire or

Gas leak happens.

Security Operators

These systems give us the holistic view of the plant operations and help us

ensure protection of our company’s assets. We know where each employee is and

can quickly get to them in case of any incident, fire or

gas leak.

7

Safety Manager, DCS and F&G I/O’s example

•Status of Fire & Gas application and devices can be viewed online •Ease of maintenance due to direct access to predefined data •Maintenance and calibration for field-equipment can be done online without the need of shutting down the controller or process •Maximum availability due to redundant concept

8

Universal remote IO units in safety manager

DI AI DO AO

ATEX zone 2

• 32 channel HART universal I/O module • AI, AO, DI and DO signals on any channel • Universal two wire termination

• Standard line monitoring, SIL 3 certified • Extreme temperature range : -40 to +70 deg C • Ethernet – up to 100km / 6 switch levels

• Universal Safety I/O field solutions: • Intrinsic Safe solutions (MTL, P&F) • Exd housing for ATEX zone 1, Class 1 Div 1

• Ideally suited for • Tank farm F&G interface • Oil wells and manifolds, Pipeline applications

• Modbus Master in Safety Manager

9

• Addressable and reliable protection • 159 Sensors &159 Modules Per loop, up to 10 loops • BACNET/MODBUS Gateways. • Full range of sensors & devices. • Sensor condition monitoring/reporting • High reliability through Closed loop technology

XLS 2000 – Intelligent Fire Alarm Panel

10

Flexible Networking & Notification options

DAA-50 Series Amplifiers (up to 32)

DAL (Digital Audio Loop)

Inputs ( Manual Emergency Pushbuttons

Output ( Strobe Lights etc)

Speakers

WIP Phones

LED signs (adjacent to Emergency exits)

Mass delivery messages

Notifier Fire Alarm Panel

Digital Voice Command

Notifier Fire Alarm Panel

Digital Voice Command

High Speed Networking Noti-

Fire-Net (over Fibre / Copper)

Reliable Peer to Peer Communication

11

Honeywell Gas Detectors – Flammable,Toxic, O2

12

Sensing Technology

SearchPoint Optima Plus Infrared Gas Sensors from Honeywell Analytics

• Fully approved by TÜV for SIL Level 2 • HART® - Digital Data over 4-20 mA

• Perform device diagnostics and proactive maintenance from a central location

• Finally, a HART® interface that speaks the language of gas detection • Easy to understand messaging on your HART® host

device • Eliminate time wasted referring to manuals to “decode”

generic HART® messages

• Autosensing current sink or source – simplifies the offering

New!!

1995 Searchpoint Optima

1999 Searchpoint Optima Plus

2008 Performance approval to EN61779

2012 HART®

TÜV SIL2 Performance approval to EN60079-29-1 & FM 6310, 6320 Software approval to EN50271:2010 Autosensing Sink/Source

13

Universal Gas Transmitter Interface

XNX Transmitter Platform from Honeywell Analytics • Fully approved by TÜV to SIL Level 2 • HART® - Digital Data over 4-20 mA

• Perform device diagnostics and proactive maintenance from a central location

• Finally, a HART® interface that speaks the language of gas detection • Easy to understand messaging on your HART® host device

• Optional Foundation Fieldbus, MODBUS or Alarm Relay Outputs.

• Interfaces with complete range of Honeywell Analytics Sensing Technology

New!!

14

Flame Detectors

• Types of detector available – Triple IR + Vis – UVIR + Vis – UV2IR + Vis

• Detectors alarm to… – dirty, sooty fires – O2 enriched or O2 deficient fires

• Not dependent on the 4.3µ CO2 spike • Wide Band IR detectors are not blocked

by dew, moisture or guard bands . • IECEx Certified for Hazardous Areas

New!! FSX Range of Flame Detectors by HA Fire Sentry

15

Sensing technology – Multi - Criteria Detector

• Multi-Sensor technology Detector with Smoke, Heat, Carbon Monoxide (Co) and Flame elements.

• Sure alarm combining four elements of a fire. • Carbon monoxide sensor operates

independently. • High immunity to unwanted alarms. • Twin LED indicators providing 360° visibility • Totally supervised & addressable.

New!!

16

HSSD Sensing technology – VIEW New!!

• Higher sensitivity than normal optical detectors • Applications for very early detection • Addressable detector, common base and on the

same detection loop • PINNACLE detectors are ideal for:

• Computer rooms • Control rooms, rack rooms • Telecommunication facilities • Any location where very

early detection is critical

17

• Video is an accurate and safe way to quickly asses a situation in the field • A leak in hazardous product Tank /sphere can be disastrous for nearby areas • Light conditions may not always be favourable to notice or track the leak • Identifying the actual level in the product tank / sphere could be challenge using

conventional instrumentation • Verifying that a Hazardous Product Tank/sphere is actually empty before

proceeding with Maintenance works on that

Ageing Hazardous area product Spheres

Digital Video Manager application

18

Critical alarm received from gas-leak detector

A PTZ Thermal Camera will automatically turn to the alarm location

Live video automatically shown to the operator

Automatic recording is started and includes the events before the alarm (pre-recording)

Digital Video Manager: Incident response

Integration with Process Control is critical

19

You can view the recording using a popup display directly from the Alarm/Event Summary. The Station can also be configured to automatically switch to display live video for the camera.

Experion alarms and events can activate recordings from the time say a Gas Leak detector is activated.

In addition, a pre-record slice of video ( say, a duration of 2-5 mins) can also be saved to help establish what preceded the incident as well as its consequences.

20

Case I Integrated F&G Solution for a Large Refinery Project

• Honeywell Safety Manager for process areas

• Honeywell Life Safety addressable fire alarm panel supporting IS and Non-IS loops, redundant communication with Safety Manager

• Honeywell Analytics Gas Detectors

• Experion PKS Work Stations (60,000 SCADA Points)

• 94 + Exproof Cameras

• Honeywell Digital Video manager integration with Experion

21

Case II – Integrated Fire & Gas System- Revamp Project

CHALLENGES • Remote Site over a large area • Obsolescence of existing equipment (detectors and system) • Revamp is coinciding with update to ESD and DCS (need for 20

years + operability) • Space constraints because parallel systems till cut-over • Consideration required to operator training and support of new

solution, need for consistency across the site, no ‘1 off’ solutions • Local and national codes must be met for system certification

22

Case II – Fire and Gas System for a Revamp Project

Honeywell Solution: • Safety Manager platform common across site but integrated through SafeNet P2P

• HW Analytics large detector portfolio for ‘one stop shop’ project execution

• Fully integrated to Experion with embedded functionality for alarm management, event collection etc

• Operator stations can view all nodes on FTE minimizing control room footprint

• FGS detector interfaces are part of standard solution and tested off-line removing any interfacing issues during commissioning

• Operators can be trained following the Experion training program applicable for ESD,DCS and FGS platforms training personnel on a single platform

• Integrated solution approved by TUV, FM, UL, etc.

• HW staged the full integration FAT reducing commissioning and cut-over time at site (only minimal system SAT required the rest of the time can be spent on field support)

23

Case III – Integrated security System at NCIG Coal Terminal

24

Coal Export Terminal – Integrated Graphic

25

• Customer Needs – Mesh network to support emergency rescue operations

– Fire rescue team equipped with mobile handheld devices with real-time video feeds from across plant

• Solution – Honeywell OneWireless™ network (50+ AP)s

– Wireless video monitoring

– Site survey and startup assistance

• Benefits – Fire rescue teams have real time information

– No dependency on other teams for rescue operations

– Use same network for other wireless applications

Case IV - Wireless application: Refinery

26

Case V - Wireless application: Gas Plant

Plant turnarounds Fence-line monitoring Personal protection Industrial hygiene

• Customer Needs – Mesh network to support perimeter deployment of Fire & Gas devices

• Solution – OneWireless™ XYR6000 universal transmitters

– Infra-red Open Path Detn Gas Detectors

– Wireless Device manager

• Benefits

27

Searchline Excel - Open Path Hydrocarbon Gas Detector

• Infra-red Open Path Detection • Certified Exd -40ºC to +65ºC • Response time < 3 seconds • Path lengths from 5 to 200m (15 to 650ft) • Measuring range 0 - 5 LEL.m • Analog and digital outputs

28

Integrated Solutions - Reduce Operations Risks • Innovative sensor and network technologies

– Wired and Wireless options – Higher safety integrity levels, sensitivity & wide bands

• Experion - Single window interface – For process, fire & safety operations and maintenance – Abnormal Situation Management (ASM) principles – Improve Operator Efficiency - Alarms, Diagnostics, Events/history

• Automated mitigation actions – Deluge & Preaction Systems FM Class 1011 &1012 – Integrated suppression systems

• Integrated CCTV systems – Visual information for better guidance, response

29

Integrated Solutions – maximize value, reduce cost

One stop Shop for Process and Non-process F&G – World class products, pre-tested, seamlessly integrated – FEED to After market services – spares, maintenance

contracts, upgrades

Improve productivity – Products, applications to reduce false alarms, be-proactive – Remote engineering, operations/ maintenance tools

Solution meeting regulatory standards – International Safety system standards – Fire panel Listing to Australian/NZ Fire Standards. – IECEx Hazardous Area Certification

30

31

Abstract

A range of applications in varied industries demand a flexible approach - from low-cost compliance options through to high end solutions designed to maximize equipment uptime – without compromise on safety. Honeywell has technologies and manufactures products that meet local regulations & safety standards that cater to most needs in Safety and Fire & Gas F&G systems.

New Gas detectors, Aspirated Smoke detection devices or Laser based detectors are just some of the reliable devices that have come together to improve safety in the process areas and associated buildings. This paper will consider the methods of implementing a fire and gas detection and protection system - standalone or integrated in the overall plant automation concept focusing on examples of how the power of integration through Experion PKS, Digital Video Manager, Safety Manager, the Security system and the Notifier Fire Alarm Panel helps organizations improve productivity, improving responsiveness to any situation, reduce incidents or mitigate risks quicker.