integrated protective solutions fgs and safety bob lee, … · 2015-09-15 · third party interface...
TRANSCRIPT
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
3 © 2014 Honeywell International All Rights Reserved3 © 2015 Honeywell International All Rights Reserved
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
4 © 2014 Honeywell International All Rights Reserved4 © 2015 Honeywell International All Rights Reserved
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
5 © 2014 Honeywell International All Rights Reserved5 © 2015 Honeywell International All Rights Reserved
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
6 © 2014 Honeywell International All Rights Reserved6 © 2015 Honeywell International All Rights Reserved
Integrated Fire&Gas, Safety and Security in action – Demo…
7 © 2014 Honeywell International All Rights Reserved7 © 2015 Honeywell International All Rights Reserved
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
8 © 2014 Honeywell International All Rights Reserved8 © 2015 Honeywell International All Rights Reserved
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
9 © 2014 Honeywell International All Rights Reserved9 © 2015 Honeywell International All Rights Reserved
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
10 © 2014 Honeywell International All Rights Reserved10 © 2015 Honeywell International All Rights Reserved
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
11 © 2014 Honeywell International All Rights Reserved11 © 2015 Honeywell International All Rights Reserved
Reference sites – Shaybah, BS–132, Manifa…
EPCs:
• Samsung
• SKEC
• JGC
• Technicas
• Hyundai
Case Study 1 – Simple Ring network FAP System
Structure
12 © 2014 Honeywell International All Rights Reserved12 © 2015 Honeywell International All Rights Reserved
Reference sites – WQ2, JAC, JRC, TG, JGSummit,
SABIC….
Case Study 2 – One–Ring network FAP System
Structure
EPCs:
• Samsung
• SKEC
• Hyundai
• Toyo
• Essar
13 © 2014 Honeywell International All Rights Reserved13 © 2015 Honeywell International All Rights Reserved
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
14 © 2014 Honeywell International All Rights Reserved14 © 2015 Honeywell International All Rights Reserved
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
15 © 2014 Honeywell International All Rights Reserved15 © 2015 Honeywell International All Rights Reserved
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
16 © 2014 Honeywell International All Rights Reserved16 © 2015 Honeywell International All Rights Reserved
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
17 © 2014 Honeywell International All Rights Reserved17 © 2015 Honeywell International All Rights Reserved
• 18 Monitoring Location (ECCC, CCR)
• 2 Supervisory Server
• 24 MFAP Cluster
• 170 SFAP/GSP
Case Study – FGS and Safety Multi–fault –
MAA architecture
18 © 2014 Honeywell International All Rights Reserved18 © 2015 Honeywell International All Rights Reserved
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
Case Study – FGS and Safety Multi–fault –
MAA extension
19 © 2014 Honeywell International All Rights Reserved19 © 2015 Honeywell International All Rights Reserved
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
Case Study – FGS and Safety Multi–fault –
MAB extension
20 © 2014 Honeywell International All Rights Reserved20 © 2015 Honeywell International All Rights Reserved
Case Study – FGS and Safety Multi–fault –
more to come…
21 © 2014 Honeywell International All Rights Reserved21 © 2015 Honeywell International All Rights Reserved
• 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)
22 © 2014 Honeywell International All Rights Reserved22 © 2015 Honeywell International All Rights Reserved
Project Organization and Execution Model
(FGS and Safety)
Customer expects One–location, one project execution plan
23 © 2014 Honeywell International All Rights Reserved23 © 2015 Honeywell International All Rights Reserved
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
24 © 2014 Honeywell International All Rights Reserved24 © 2015 Honeywell International All Rights Reserved
Thank you!
Any
Questions?
25 © 2014 Honeywell International All Rights Reserved25 © 2015 Honeywell International All Rights Reserved
Thank you!
Any
Questions?
Supplements slides
on
Honeywell product and solutions capability
26 © 2014 Honeywell International All Rights Reserved26 © 2015 Honeywell International All Rights Reserved
Honeywell Flame and Gas Detection Offerings What is he doing???
27 © 2014 Honeywell International All Rights Reserved27 © 2015 Honeywell International All Rights Reserved
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
28 © 2014 Honeywell International All Rights Reserved28 © 2015 Honeywell International All Rights Reserved
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
29 © 2014 Honeywell International All Rights Reserved29 © 2015 Honeywell International All Rights Reserved
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
30 © 2014 Honeywell International All Rights Reserved30 © 2015 Honeywell International All Rights Reserved
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
31 © 2014 Honeywell International All Rights Reserved31 © 2015 Honeywell International All Rights Reserved
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
32 © 2014 Honeywell International All Rights Reserved32 © 2015 Honeywell International All Rights Reserved
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
33 © 2014 Honeywell International All Rights Reserved33 © 2015 Honeywell International All Rights Reserved
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
34 © 2014 Honeywell International All Rights Reserved34 © 2015 Honeywell International All Rights Reserved
- 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
35 © 2014 Honeywell International All Rights Reserved35 © 2015 Honeywell International All Rights Reserved
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
36 © 2014 Honeywell International All Rights Reserved36 © 2015 Honeywell International All Rights Reserved
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
37 © 2014 Honeywell International All Rights Reserved37 © 2015 Honeywell International All Rights Reserved
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…
38 © 2014 Honeywell International All Rights Reserved38 © 2015 Honeywell International All Rights Reserved
Remote or local USIO design concept
39 © 2014 Honeywell International All Rights Reserved39 © 2015 Honeywell International All Rights Reserved
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
40 © 2014 Honeywell International All Rights Reserved40 © 2015 Honeywell International All Rights Reserved
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
41 © 2014 Honeywell International All Rights Reserved41 © 2015 Honeywell International All Rights Reserved
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
42 © 2014 Honeywell International All Rights Reserved42 © 2015 Honeywell International All Rights Reserved
Thank you!
Any
Questions?