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Safety System Lifecycle Support with Safety Manager and
Fire & Gas Update Erik de Groot, Marketing Manager Safety Systems
Jeff Kuhn, HPS Americas Fire and Gas COE
2 © 2015 Honeywell International All Rights Reserved
• Safety Manager general overview
• FSC migration details
• Industrial Fire & Gas Solutions
Agenda
3
Meet the safety standard IEC 61508/11
• Safety Manager is TUV SIL 3 approved out of the box
• Supports two IO families:
– Chassis IO
– Universal Safety IO
• Centralized and distributed applications
• Supports TUV approved online
modification technique
–Application changes
–Hardware changes
–Hardware additions
–Release migrations
Safety Manager SIL 3 out of the box
4
• High density 32 channel redundant universal I/O module
• Supports AI, AO, DI and DO signals on any channel
• Universal two wire termination
• Standard line monitoring
• TÜV SIL1, 2 and 3 certified
• Compatible with existing Safety Manager
installations
• Extreme temperature range
-40 to +70 degrees C,
-40 to +158 degrees F
• Ethernet – up to 100km / 6 switch levels
• Low latency SOE (1 msec)
• Supports HART pass thru
Universal Safety IO Features
Flexibility meeting project need
5
Distributed / Localized Safeguarding
• Ideally suited for:
– Well head applications or pipeline control,
– other distributed applications
• SIL 3 Universal IO technology with:
– Function Logic Diagram execution
• Safeguarding the process
– Even in the event communications to
the Safety Manager are interrupted.
• Application transparency
UNIVERSAL Safety Logic Solver
Providing more flexibility and process availability
6
Provide high reliability/availability
• Safety Manager well-proven redundancy
architecture delivering maximum:
– Safety,
– Availability, and
– Reliability
• Safety Manager A.R.T. option
– Multi fault tolerance on I/O buss
– Targeted for:
• Projects where timely maintenance cannot be offered:
– Unmanned platforms
– Lack of adequate maintenance skills
SAFETY MANAGER A.R.T.
REDUNDANT CHASSIS IO
SAFETY MANAGER A.R.T.
REDUNDANT CHASSIS IO
SA
FE
TY
MA
NA
GE
R A
.R.T
. SA
FE
TY
MA
NA
GE
R A
.R.T
.
7
Integrate with ICSS at controller an HMI level
• CEE peer-to-peer communication
• HMI Data access
• Integrated Alarm Notifications
• Console station support
Simplified engineering and maintenance
Advanced Experion Integration Experion
PKS
FSC to Safety Manager Migration
9
Business drivers
• Extend lifecycle:
Extends capital investment;
Protects intellectual property.
• Modernize the Safety System
Update to the latest safety standards;
Use most modern safety features .
Why would you migrate?
10
Extend the lifetime of your safeguarding
system
Introduce the latest safety features
Prevent a rip and replace
Maintain the safety application
Limit training for maintenance and engineering staff
Maintain all your field wiring and
devices
The Next Evolution Path – What is NEW
Revolutionary Technology Delivered in an Evolutionary Way
Protect your intellectual property by migrating your FSC system to the 21st Century safeguarding technology:
11
Focus: TPS expansion
• Safety Manager connection to the EUCN
• TÜV certified Fail Safe communication between FSC and Safety Manager
EUCN & SafeNet
Safety Manager R160 & FSC R800
Expansions & migrations
Revolutionary Technology Delivered in an Evolutionary Way
Focus: FSC migration
• Hardware migration kit(s) to replace FSC Central Parts with Safety Manager controller
• TÜV certified application migration tool for migration from FSC to Safety Manager
Hardware & Software migration
Safety Manager R160 & FSC R800
1st part 2nd part
12
Safety Manager on EUCN
Revolutionary Technology Delivered in an Evolutionary Way
Total Plant Solution
Expand your process units with Safety Manager
1st part
EHPM
LCN
NIM
EUCN / FTE
Fault Tolerant Ethernet
UCN
SM
FSC
ENIM
13
Hardware Migration Kit(s)
Maintain your IO modules, field instruments and wiring and obtain the 21st Century safety features
Hardware migration to Safety Manager
Revolutionary Technology Delivered in an Evolutionary Way
Safety Manager with Native I/O
Universal Safety IO
with Hart pass through
2nd part
FSC with Native I/O
14
Safety Manager with Safety Manager I/O
FSC with Safety Manager I/O
Revolutionary Technology Delivered in an Evolutionary Way
2nd part
ISA secure
Hardware migration to Safety Manager
Hardware Migration Kit(s)
Maintain your IO modules, field instruments and wiring and obtain the 21st Century safety features
15
Revolutionary Technology Delivered in an Evolutionary Way
2nd part
TÜV approved application migration tool
Maintain your application & save test time and training of maintenance & engineering personal
TÜV Approved Verification
Application migration
FSC
Safety Manager
Convert
Migrate
Load
Verify
Application validation
Honeywell.com
TÜV Approved Verification
17
Migration Strategy Plan
Revolutionary Technology Delivered in an Evolutionary Way
Migration Strategy and Plan
• Define a strategy
• Impact analysis, cost, how, when, detailed scheduling
• Evaluates and reports the current situation
• Configuration, application, Networking, Hardware, software, and more
Safety Audit
Migration Execution
(Phased)
• Execute the migration
• This may be a phased migration covering several years
Global Migration Core Team Today Near Future
18
Migration Roadmap (On process version)
2013
FSC Migration to Safety Manager
Safety Manager on EUCN
Revolutionary Technology Delivered in an Evolutionary Way
2nd Half 2015
Off-process 2014
Industrial Fire & Gas Solutions
Jeff Kuhn, HPS Americas Fire and Gas COE
20 © 2015 Honeywell International All Rights Reserved
• Fire and gas systems (F&G) are the second largest process safety application based upon revenue and typically have the most I/O points of all safety applications - ARC Process Safety Systems 2013
• In 2012 & 2013, the total value of the 7 largest losses in the hydrocarbon industry caused by fire / explosion exceeds US$2 Billion ($2,000,000,000) - Marsh Report; 23rd Edition
• Safety incidents cost the industry worldwide at least $10B per year - ASM Consortium
Industrial Fire & Gas Statistics
21 © 2015 Honeywell International All Rights Reserved
• In today’s competitive environment, a single safety
incident can cause tremendous damage to the brand
image and profitability of an industrial facility
• Process industry organizations worldwide are looking
to: ‒ Provide safe operation for personnel and assets
‒ Minimize their liability by deploying advanced technology to
address risk
‒ Implement technical solutions that comply with F&G codes,
standards and local regulations
‒ Ensure continuous production and optimized project
execution with reduced engineering costs and faster plant
startup
Challenges in the Process Industry
22 © 2015 Honeywell International All Rights Reserved
F&G in an Industrial Facility
23 © 2015 Honeywell International All Rights Reserved
Honeywell´s Fire & Gas Offering
• F&G Solutions for the
Process Area
‒ Detect
Gas detectors, Flame detectors,
Smoke detectors, Pull Stations/
Manual Call Points
‒ Control
Safety Manager, HS81,
Suppression & Releasing
‒ Respond
Speakers, Beacons & Horns,
LED Signs, Graphic Package,
ESD, Mass Notification Systems
• F&G Solutions for Non-
Process Areas, Control
Buildings & Administrative
Complex
‒ Detect
Smoke/heat detection,
Aspiration, Pull Stations/Manual
Call Points
‒ Control
HS81, XLS, Suppression &
Releasing
‒ Respond
Speakers, Beacons & Horns,
LED Signs, Graphic Package,
Mass Notification Systems
24 © 2015 Honeywell International All Rights Reserved
Honeywell – One Stop Shop in F&G
25 © 2015 Honeywell International All Rights Reserved
Honeywell´s New F&G Controller
• H-S81-HS ‒ Multiple Cabinet Sizes
‒ Floor Mount or Wall Mount
‒ Marine Listing in Progress
‒ SIL2/SIL3 Option
‒ UL864/NFPA 72 Option
‒ EN54 Option
‒ Analog I/O*
‒ Digital I/O*
‒ Addressable I/O*
‒ Suppression Releasing*
*All on one Rack
26 © 2015 Honeywell International All Rights Reserved
Honeywell´s new F&G controller
27 © 2015 Honeywell International All Rights Reserved
4-20mA Analog Input Options
• 1, 2 or 8 4-20 mA inputs
• Direct reading on display
(1 or 2 input module)
• Connection of
toxic/flammable gas, and
oxygen deficiency sensors
• 2 alarm thresholds per input
• SIL 2 certified sensors
available
28 © 2015 Honeywell International All Rights Reserved
Conventional FA Input Options
Different brands and types of detectors accepted, even if already
installed in the building/area
32 detectors per line (as per UNI 9795 standard)
Short and open circuit monitoring
Pre-alarm, alarm, alarm verification on each line
29 © 2015 Honeywell International All Rights Reserved
Addressable Loop Options
Ring type lane
(loop).
Detection and
control function on
the same loop
Modules with
different
manufacturer
protocols in the
same panel
SIL 2 certified
detectors available
30 © 2015 Honeywell International All Rights Reserved
Output Modules
• Line monitoring per UL864
and NFPA 72
• Card and circuit level
diagnostics
• Audible, Visual, Relay,
Extinguishing and other
control functions.
• Releasing logic for Fire
Suppression Systems
• Up to 64 Releasing Zones
31 © 2015 Honeywell International All Rights Reserved
Hot Swap Capability
• Front plug-in/out cards
• Automatic monitoring of
cards and CPU fault
• Automatic and safe disabling
of malfunctioning cards
• Card can be hot swapped
• CPU auto-configures and
checks new card
• Power & CPU can be
duplicated for automatic fall-
over configuration
32 © 2015 Honeywell International All Rights Reserved
Flexible F&G Networking
33 © 2015 Honeywell International All Rights Reserved
Honeywell´s flexible “All-in-One” solution
• Unique Multi-functional
Controller ‒ Smoke, Flame, Gas,
Extinguishing
• Meets major global
Certifications ‒ UL864/NFPA72, EN54,
IEC61508, GOST-R, Marine
• Advantages ‒ Three systems in one
solution
‒ Easier to deploy and service
‒ HOT SWAP/Fault tolerant
‒ SIL2/3, UL & EN Compliance
‒ Redundancy
‒ Can be Fully Integrated with
PLC, DCS, SIS or other third
Party systems
3 independent systems combined in
one flexible “All-In-One” solution
34 © 2015 Honeywell International All Rights Reserved
F&G Solutions – Where do you find us?