INTEGRATED FIRE & GAS SOLUTIONS FOR PLANT & PERSONNEL SAFETY · INTEGRATED FIRE & GAS SOLUTIONS FOR PLANT & Moataz Ziadi PERSONNEL SAFETY October 2017. ... Services and Training •Training

Honeywell Technology Summit Kuwait

Honeywell Technology Summit - Kuwait

INTEGRATED FIRE & GAS SOLUTIONS FOR PLANT &

PERSONNEL SAFETYMoataz Ziadi

October 2017

Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.

Moataz Ziadi

EMEA Plant & Personnel Safety Pole Leader

Based in Abu Dhabi, UAE

Electronics and Communication Engineer

Joined Honeywell at 1996

- 9 years in Operation (Projects Lead Engineer) mainly for Safety System.

- 12 years in Consultation, Business Development and Sales


Agenda

Protecting People, Assets and Environment through fully Integrated Fire & Gas Solution

- Challenges in the Process Industry

- International codes and standards

- Fire & Gas in an industrial Facility

- Honeywell´s industrial Integrated F&G solutions

- Case Study – KNPC

- Honeywell F&G portfolio overview

- Summary and Q&A

2


Agenda








- Summary and Q&A

3


Some statistics around industrial F&G

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 $1

Billion- Marsh Report; 23rd Edition

Safety incidents cost the

industry worldwide at least $10

Billion per year- ARC Consortium

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 $1

Billion- Marsh Report; 23rd Edition

Safety incidents cost the

industry worldwide at least $10

Billion per year- ARC Consortium

4


Safety challenges

Need for Fire & Gas System

Fire & Gas is a Mitigation System (ESD preventive) – Incident already happened (Reduce consequences of a

hazardous event after it occurred);

Main Objectives to protect Personnel, Environment, and Plant (Assets)

Achieved by:

Detection

Fire (Smoke, Heat, Flame)

Gas (Toxic, Flame)

Alert

Alarms

Evacuation

Mitigate Incident Impacts

Suppression

Shutdown

Reliable Fire & Gas System

Improve Plant Safety

• Full Coverage and Early Detection

• Accurate locations and Type

• Automated Mitigation Actions

Improve Plant Reliability

• Reduce Down Time

• No False Alarms


Safety challenges

Reliable Fire & Gas System

Improve Plant Safety

• Full Coverage and Early Detection

• Accurate locations and Type

• Automated Mitigation Actions

Improve Plant Reliability

• Reduce Down Time

• No False Alarms

To be Achieved by:

Following Codes & Standards

Products and Solutions selection…..


Agenda








- Summary and Q&A

7


International codes and standards

Following Codes and Standards is a legal obligation in many countries

Codes are used to ensure the products are selected and

used correctly; details the installation, locations, spacing,

design, commissioning . etc

Installation Codes

Product specific standards are functional testing and

performance requirements:

Product Standards

NFPA 72

(US code - National Fire Alarm

Code)

UL Standards

(Under writers laboratories –

US Approval)

BS 5839-1

(UK code - British Code)

EN 54 Standards

(European - EU Approval)

Federal Law 123

(Russia)

GOST

(Russia)

8

http://www.bsi-global.com/

http://www.bsi-global.com/


Installation Codes

Typical area

of room

protection

Maximum

radius of

protection

21’

15’ 15’

15’15’

30’

30’

At least 90“ (229 cm)

At least 6” (15 cm)

50' x 50’

40' x 40’

30' x 30’

20' x 20’

• BOQ of F&G devices recommended to use

• Location of the F&G devices

• Type of detectors / working principle

Non- Process Area - Straightforward


NFPA and BS do not cover Fire & Gas detection in Process Areas.

Process Area

Performance / Risk Assessment Process Area Fire & Gas design in accordance with IEC 61511 and ISA84

Specify and Verify Performance Targets

• SIL requirements (Risk Identification and SIL Determination)

• Availability

• Detector Coverage

-IEC: International Electrotechnical Commission, the world's leading organization prepares and publishes

International Standards for all electrical, electronic and related technologies.

• IEC 61508 – Functional Safety of Electrical/Electronic/Programmable Safety Related Systems

• IEC 61511 – Functional Safety: Safety Instrumented Systems for the Process Industry Sector

-ISA: International Society of Automation, sets the standard for Automation

• ISA S84.01 – Application of Safety Instrumented Systems for the Process Industries (Adapted the IEC 61511)

• Instrumented Systems for the Process Industry Sector

Installation Codes


Identify Requirement

for FGS

FGS Zone Definition

Determine FGS

Performance Requirements

Verify Detector Coverage

Verify FGS Availability

Modify Design

(if required)

Develop FGS Philosophy

• BOQ of F&G devices

• Location of the F&G devices

• Type of detectors / working principle

• Redundancy for Availability

• SIL rating

• Voting consideration

• Shutdown functions

Outcome of FGS Design workflow:

Typical workflow for FGS Design


Agenda








- Summary and Q&A

12


What is Fire and Gas system

F&G System function to Detect, Alert and Mitigate incidents impacts

DetectionLogic

Solver

Alarm,

Mitigation

&

Protection

Fire Detection• Smoke

• Heat

• Flame

• Manual Call point

Gas Detection• Toxic

• Combustible

• Flame

• Manual Call Point

Or

Fire Alarm

Panel

System

Logic Solver

Alarm Lists & Alarm Display

Notification Appliances

(Beacons, Sounders,

PAVA)

Fire Suppression System

Safety Shutdown System

13


Fire & Gas in an industrial facility

F&G for Process area (1, 2, 3)

• DETECT

- Gas detectors, Flame detectors, Smoke

detectors, Pull stations/ Call points

• CONTROL

- Safety System, Suppression & Releasing

• RESPOND

- Speakers, Beacons & Horns, ESD, LED,

Graphic

F&G for Non-Process Areas (4)

• DETECT

- Smoke/heat detection, Aspiration, Pull

stations/ Call points

• CONTROL

- XLS, Suppression & Releasing

• RESPOND

- Speakers, Beacons, Horns, LED, Graphic

Continuously monitor Heat, Smoke and Gas levels within the plants,

To provide early warning of abnormal situation before it becomes a hazard.

14


Layers of Protection

15

Process under Control

Protection Layers (Relief Valves etc.)

Fire and Gas System

Emergency Shutdown System

Distributed Control System

Mitigation

Prevention

Control


Agenda








- Summary and Q&A

16


Honeywell’s holistic approach to Fire & Gas

17

+

Honeywell Process & Life Safety Solutions

TOTAL FIRE &

GAS OFFERING

Gas Detection Systems

Sensors Actuating Devices

Fire Control Systems

EN

UL

PAVA

Honeywell uses a layered, yet integrated and holistic approach to Fire & Gas that includes our own leading

Technologies, Consultation, Design, installation and support Service solutions

http://www.coopermedc.com/products/beacon-strobes/th12



Honeywell’s holistic approach to Fire & Gas

Consultation & FEED

• Analysis and Risk Assessment

• Recommendation on Type,

quantities and locations of

F&G devices

• Support in F&G specifications

• Site Survey and inspections

• Following Codes &

Standards

Design & Engineering

• Basic Design

• Detailed Design

• Engineering

Installation & Commissioning

• Installation

• Commissioning

• Validation

• Integration

Services and Training

• Training

• Full Lifecycle Services

• Single Window of contacts

TOTAL

FIRE & GAS

SOLUTION

18


Honeywell one-stop shop F&G supplier

Field Equipment• Gas & Flame Detectors

• Addressable Fire Sensors & Devices

• Notification Devices

• HSSD point type or Aspirating early fire

detection

• Process monitoring video systems

• Suppression Systems

Services

Human Interface

Logic Solver &

Networking Technologies• Safety consulting services including

Safety audits, Hazop and SIL verification

& Validation

• Fire system design services

• Project services including Design,

Engineering & Commissioning

• Project management

• Lifecycle support services & training

• Experion Orion

• Experion industrial security

• Digital video manager

• Other advance applications like Alarm

manager, PHD, eServer, Experion

collaboration station

• First responder interface

• SIL-3 solutions: Honeywell safety systems

• Fire alarm panels

• Public address/voice alarm systems

• Fire Networks, Bus & Ring Topologies

• OneWirelessTM Infrastructure

HoneywellOne-Stop

F&G Supplier

19


Integrated Control

& Safety Solutions

(ICSS)

• Experion (DCS)

• Safety Manager

(ESD, F&G & BMS) (P2P)

• Gas & Flame Detectors

FGS ESD DCS

IEC61511BMS

IND

SEC

NFPA/EN/BS/ATEX

Integrated F&G

and Security

Solutions (ISS)

• FAS

• Addressable devices

(Smoke & Heat Detectors)

• Digital Video Manager

(DVM)

F&G Solution

GAS

Flame

One Honeywell Integrated Fire & Gas Solution

FAS

Smoke

Heat



Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved. Honeywell Integrated Unified Solution

Area 1 Area 2

Area 4 Area 3

Safe-Net

ESD & FGS

FTE

Fire-Net

FAS



• DSA (Distributed Server Architecture) : Seamless Integration among EPKS Servers

• Data Transfer from Server to Server without any additional engineering work

• SafeNet: TUV SIL3 Certified Communication Network

• XLSNET: XLS System Peer to Peer communication Network

- Data Exchange between XLS Panels

- Logic Link Between XLS Panels

- Remote Access and configuration of XLS Panels.

• Systematic Graphics Hierarchy (overview to detail) – Easy Navigation of Fire Alarms

• Detector level information available from operator station.

• Full access to FAP and Detectors (Bi-Directional)

Honeywell Fully Integrated Solution:



• Single Operator Station: Improve Operators efficiency,

Single window for Operation and Maintenance.

Unified Control and Safety Applications.

• Direct communication, no servers or any H/W is required to interface.

• Full access to the Diagnostics.

• Full access to detailed Data, and information.

• Time synchronization.

• Exchange Real Time data.

• Common SOE.

• Common Alarms and Events




CAPEX

• Easy Configuration and Engineering, Huge cost saves in Engineering. (50%)

• Huge cost and time saving in Testing, Commissioning and Startup, (50%)

• Allows multiple systems to communicate together through the same Network.

• Common Workstation for all systems Applications


OPEX

• Running Cost, Upgrades, Expansions, Compatibilities, etc.

• Reduce Maintenance cost, less H/W, etc.

• Reduce training cost.



EBI or Experion Server

EBI or Experion Stations

Local Area Network

DVM Databaseand Camera Server

DVM Clients

Analog Cameras

Camera Streamers

Digital Cameras

Alarm Activation from Detectors

Display Video of Alarm Recording Video of Alarm

Fire & Gas System

Video Network

Fixed or Pan, Tilt, ZoomCameras Supported

Alarm!

Cameras moves to the Alarm location

Fire & Gas and DVM Integration

• Improve Operators Efficiency & Awareness

- Automated actions

- Alarm video from Operator Station

- Improve incident response time.

- Avoid unnecessary Shutdowns



27

• Integration is critical when every second counts.

SECTION

2

Associated PTZ Camera automatically turn to the

alarm location

Automatic recording started

Operator Clicks on Alarm to Access Camera Page

Gas Leak Alarm Triggered

Experion PKS Displays the Alarm

Alarm video displayed on dedicated station monitor

SECTION

2

Fire & Gas and DVM Integration



Agenda








- Summary and Q&A

28


KNPC - Kuwait

29

Challenges and Requirements• Replacement of ageing Fire & Gas Detection, Alarm and suppression Systems

• Huge amount of Data Integration from different type of Systems and Panels

• Ensure Operators awareness of the entire plants Fire & Gas status, to pro-actively avoid an incident or fast

respond to any occurrence,

• Integrated Solution covering the Three Refineries (Shuibah, Mina Al-Ahmadi, Mina Abdullah) along with

Sabhan & Ahmadi Depots

Benefits and Achievements• State of the Art, modern, comprehensive Fire Detection and Alarm system covering the entire facilities

through Continues Monitoring and Early Detection solution, improved KNPC plant Safety, Reliability and

Productivity

• Control and monitoring of the entire Plants from the Central Control room and essential locations.

• Automated Alarms & Responses (Suppression)along with tight integration with Safety and Control Systems,

significantly reduced response time and dependence on operators actions.

• Reached higher standard of Safety that also meets all relevant national and international standards.

Largest Fire & Gas Project delivered by Honeywell – 2012

Upgradation of Obsolete Fire & Gas Detection, Alarm and Suppression System at KNPC Sites including the

Phase out of Halon System


KNPC - Kuwait

30

Honeywell SolutionThis project should be treated as an unprecedented project in the fire and gas history with extremely huge

numbers of Fire Alarm Panels and Fire & Gas and Alarm devices accommodated.

Design, Supply, Installation and Commissioning of Fully integrated solution for Process and Non-Process

Areas with.

Supply:

• 11 Experion servers & 40 Operator Stations

• 60+ Safety Manager (MFAP)

• 190+ Fire Alarm Panels XLS3000 (SFAP)

• 180+ Gas Suppression Panels XLS140 (GSP)

• 38,000 Gas & Flame detectors, Addressable sensors, notification devices,

• High Sensitivity Smoke Detection (HSSD)

Integration:

• Interface with 140+ different 15 brands of existing F&G systems.

• Experion based Fire & Gas supervisory system to the Honeywell DCS in all the three Refiners

• Experion based Fire & Gas supervisory system to Emerson and Invensys DCS systems in Mina Al-Ahmdi

refinery





KNPC - Kuwait

31

Block Diagram




Safety Manager

XLS3000

Fire StationCCR

FA Main FA HMI

MFACP

LFACP

ICSS Main

FGS ESD DCS

• Redundant Ethernet FO FTE

• Dual Ring FO

- Modbus + XLS-Net

- Modbus

Flame Det.

Gas Detector

MCP

Heat Det.

Horn/Strobe

FGS HMI


KNPC - Kuwait

32

Typical Architecture




Fault-Tolerant Ethernet

Experion PKS

ESD

Safety System

Operator

Station

4-20 ma Devices

DSA to other

EPKS Servers

MFACP

(Safety Manager)

PRESS HERETRYKK HER

KNUS GLASSET

BREAK GLASS

Gas detectors

Fire detectors

Sounders & beacons

SFACP

(XLS)

Supervisory System

Fire Water Pump Control

Deluge Valve Control

Common Alarm to ECCC / CCR


Agenda








- Summary and Q&A

33


Traditional Field Wiring & Marshalling

DI

AI

DO

AO

DI

AI

DO

AO

DI

AI

DO

AO

Junction

boxes

Safety Manager

System Integration Cables

Junction

box

Multi

Core

Cables

Marshalling

Cabinet


Fiber optic

Fiber optic

Fiber optic

Soft Marshalling – Reinventing field wiring


CAPEX savings

• External field power

• Various I/O modules

• Junction boxes, Marshalling cabinets, Field auxiliary room (None or smaller)

• Home run cables, Cable ducts and infrastructure

• Expansions do not require additional multi core cables

Fire & Gas Controller – Safety Manager & Remote I/O

OPEX savings

• Simplified hardware engineering loop drawings

• Reduced test time

• More efficient commissioning and start up,

• Reduced maintenance cost

• Increase Flexibility

Easily reduces cost with 1000 USD/channel

Honeywell´s industrial F&G solution


High density 32 channel redundant universal I/O module• Supports AI, AO, DI and DO signals on any channel

• Channel definition through application programming

TÜV SIL3

Extreme Temperature range -40 to +70 degrees C,

Line monitoring and short circuit detection on every channel

Sequence of event support

TÜV approved online modification technique

HART pass thru

Distance Up to 100Km

Remote I/O with logic solving capability (RUSLS)• Function Logic Diagram execution

• Safety function unaffected during Communication loss,

• or Safety Manager shutdown

Fire & Gas Controller – Safety Manager & Remote I/O

One I/O module instead of 4 different module types



Remote I/O supports typical F&G equipment

like:

• Gas-detectors

• Fire-detectors

• Smoke / Heat detectors

• Sounders

• Beacons

• Etc.

Supports AI, AO, DI and DO signals on any

channel

Channel definition through application

programming

Safety Manager Remote I/O – Fire & Gas

AI

AI

DI

DO

DO DI

AI



MVIP Program

• Safety Manager / FSC certified interfaces to wide range

of Fire, Gas and Flame detectors in addition to other

devices like Beacons and Sounders

• Provides Standard tested Wiring, Function Blocks

• To improve overall system performance, Enhance

System Diagnostics and reduce engineering costs

Multi Vendor Interface Program (MVIP)


Complying to the local & International Codes &

Standards,

Seamlessly integrate with Experion via EIS/DSA to

reduce engineering time

Fire Alarm, Gas detection, VA & Fire Phone System

Fire Suppression Capabilities.

1 to 10 loops, Up to 318 (device per loop).

Each Loop control modules contains processor

Degraded Mode.

Loop length: up to 3810 m

Totally modular, expandable.

Networkable – up to 200 FACP or Nodes, True peer-to-

peer communications. Accommodate Repeaters.

Fire Alarm Panel


http://acsdashboards.honeywell.com/sites/MarcomFieldGuide/Fire Life Safety/XLS140-2_sm.jpg

http://acsdashboards.honeywell.com/sites/MarcomFieldGuide/Fire Life Safety/XLS140-2_sm.jpg


Earliest possible warning – 0.0015obs/m2

Highest levels of false alarm immunity- 67% improvement (Smoke &

IR for Dust differentiation)

Cost effective covers up to 28,000ft²

Addressable & Conventional

Modbus Communication (DCS & ESD)

7 Sensitivity levels with 3 years filter,

41

FAAST (Fire Alarm Aspiration Sensing Technology) - HSSD

First Stage FilterSecond Stage Filter

Dual laser detection Chamber



42

Up to 50 times more sensitive than a standard photoelectric Smoke Detector.

Advanced Warning Addressable Combustion Sensing (AWACS) minimizes nuisance alarms

Provides comparable performance to current aspirating technology at a lower cost using an

extremely bright, controlled laser, Detects obscuration to .02%/Ft.

Applications: Critical areas, Cabinets, Computer rooms, Cable rooms, Auxiliary rooms etc.

Wide sensitivity range,

Pinnacle Detector (Laser-Ultra high Sensitive)



43

Multi-criteria SMART range• True multi-criteria range for highest performance systems

• Microprocessor combination of sensing elements

• Configurable sensitivity for many applications

• Provide Early Detection

• Reduce False Alarms

Smart Detectors

SMART2

•Optical smoke detection

•Thermal detection

SMART³



• Infra-Red flame detection

SMART4



• Infra-Red flame detection

•Carbon monoxide detection

Early Detection Without False Alarm



44

VARIODYN®

D1VAPA System

Headend

Inputs Outputs

• Smart Tool for Alarming and Orderly Safely People Evacuation

in the shortest possible time during emergency situations

• Only13% of people react in a timely manner to a tone alarms,

While

• 75% of people react to a voice message explaining the nature

of the emergency

Public Address Voice Alarm (PAVA)

• Complete systems for Voice Alarm and Public Address

• Modular structure, VARIODYN® D1 for the most diverse areas of application to compact complete systems..

• Real time fully monitored; Interface to fire panels,

• Different Frequencies,

• Voice Alarms (Live and Recorded messages)

• Network based, scalable, High quality audio





Revolutionary navigation tool for firefighters and emergency responders

A touch screen PC that displays critical information, Fire events, Origin of a fire, Spread of a fire,…etc.

Makes emergency operations safer and more effective

Provides Fire Operator incident location and best route to destination,

Graphically displays active devices and potential hazards

Life Cameras

First Responder Display



First Responder Display



Agenda








- Summary and Q&A

47


Early Detection

Accurate locations and Type (Process & Non-Process)

Real Alarms – No False Alarms

Automated Mitigation Actions

Live Video and vision

Proactive decisions to minimize losses

Honeywell Fire & Gas System will provide:



What will you do in case of

Fire or Gas incident

occurs…?

Let’s Discuss at the

Emergency Response

session after lunch…

Hope to see you all.


50

Thanks,

Moataz Ziadi

Q&A

Documents

INTEGRATED FIRE & GAS SOLUTIONS FOR PLANT & PERSONNEL SAFETY · INTEGRATED FIRE & GAS SOLUTIONS FOR PLANT & Moataz Ziadi PERSONNEL SAFETY October 2017. ... Services and Training •Training