Integrated Fire and Gas Solution For People and Plant Safety

Honeywell Technology Summit Kuwait
INTEGRATED FIRE & GAS SOLUTIONS FOR PLANT &

Moataz Ziadi
October 2017 PERSONNEL SAFETY
Honeywell Technology Summit - Kuwait
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
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.

2
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

3
Agenda
- Summary and Q&A

4
Some statistics around industrial F&G
In 2012 & 2013, the total value

of the 7 largest losses in the
hydrocarbon industry caused
Fire and gas systems (F&G)
by fire / explosion exceeds $1
are the second largest process
Billion
safety application based upon - Marsh Report; 23rd Edition
revenue and typically have the
most I/O points of all safety
applications
- ARC Process Safety Systems 2013
Safety incidents cost the

industry worldwide at least $10
Billion per year
- ARC Consortium

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 Alert Mitigate Incident Impacts
Fire (Smoke, Heat, Flame) Alarms Suppression
Gas (Toxic, Flame) Evacuation Shutdown
Reliable Fire & Gas System
Improve Plant Safety Improve Plant Reliability

• Full Coverage and Early Detection • Reduce Down Time
• Accurate locations and Type • No False Alarms
• Automated Mitigation Actions

Safety challenges
To be Achieved by:
Following
Reliable Codes & Standards
Fire & Gas System
Products and Solutions selection…..
Improve Plant Safety Improve Plant Reliability
• Full Coverage and Early Detection • Reduce Down Time
• Accurate locations and Type • No False Alarms
• Automated Mitigation Actions

7
Agenda
- Summary and Q&A

8
International codes and standards
Installation Codes Product Standards

Codes are used to ensure the products are selected and Product specific standards are functional testing and
used correctly; details the installation, locations, spacing, performance requirements:
design, commissioning . etc
BS 5839-1 EN 54 Standards
(UK code - British Code) (European - EU Approval)
NFPA 72 UL Standards
(US code - National Fire Alarm (Under writers laboratories –
Code) US Approval)
Federal Law 123 GOST

(Russia) (Russia)
Following Codes and Standards is a legal obligation in many countries

Installation Codes
Non- Process Area - Straightforward Maximum

radius of
• BOQ of F&G devices recommended to use Typical area
of room
protection
protection
• Location of the F&G devices
• Type of detectors / working principle 21’
At least 6” (15 cm)
15’ 15’
’
30
At least 90“ (229 cm) ’

30
20' x 20’
30' x 30’
40' x 40’
50' x 50’ 15’

15’

Installation Codes
Process Area
 NFPA and BS do not cover Fire & Gas detection in Process Areas.
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

Typical workflow for FGS Design
Identify Requirement
for FGS
Develop FGS Philosophy
FGS Zone Definition
Outcome of FGS Design workflow: Determine FGS

Performance Requirements
• BOQ of F&G devices
• Location of the F&G devices
• Type of detectors / working principle Verify Detector Coverage
• Redundancy for Availability

• SIL rating Verify FGS Availability
• Voting consideration
Modify Design
• Shutdown functions (if required)

12
Agenda
- Summary and Q&A

13
What is Fire and Gas system
Alarm,
Logic Mitigation
Detection
Solver &
Protection
Alarm Lists & Alarm Display

Fire Detection
• Smoke Logic Solver Notification Appliances
• Heat (Beacons, Sounders,
• Flame PAVA)
• Manual Call point Fire Suppression System
Safety Shutdown System
Gas Detection Or
• Toxic Fire Alarm
Panel
• Combustible System
• Flame
• Manual Call Point
F&G System function to Detect, Alert and Mitigate incidents impacts

14
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.
15
Layers of Protection
Protection Layers (Relief Valves etc.)
Mitigation
Fire and Gas System
Emergency Shutdown System Prevention
Distributed Control System

Control
Process under Control

16
Agenda
- Summary and Q&A

17
Honeywell’s holistic approach to Fire & Gas
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
Fire Control Sensors Gas PAVA

Systems Actuating Detection
Devices Systems
UL
EN + TOTAL FIRE &

GAS OFFERING
Honeywell Process & Life Safety Solutions

18
Honeywell’s holistic approach to Fire & Gas
Consultation & FEED Design & Engineering

• Analysis and Risk Assessment • Basic Design
• Recommendation on Type, • Detailed Design
quantities and locations of • Engineering
F&G devices
• Support in F&G specifications
• Site Survey and inspections
• Following Codes & TOTAL
Standards FIRE & GAS
SOLUTION
Installation & Commissioning Services and Training
• Installation • Training
• Commissioning • Full Lifecycle Services
• Validation • Single Window of contacts
• Integration

19
Honeywell one-stop shop F&G supplier
Human Interface Field Equipment

• Experion Orion • Gas & Flame Detectors
• Experion industrial security • Addressable Fire Sensors & Devices
• Digital video manager • Notification Devices
• Other advance applications like Alarm • HSSD point type or Aspirating early fire
manager, PHD, eServer, Experion detection
collaboration station • Process monitoring video systems
• First responder interface • Suppression Systems
Honeywell
One-Stop
F&G Supplier
Logic Solver &
Services
Networking Technologies
• Safety consulting services including
• SIL-3 solutions: Honeywell safety systems Safety audits, Hazop and SIL verification
• Fire alarm panels & Validation
• Public address/voice alarm systems • Fire system design services
• Fire Networks, Bus & Ring Topologies • Project services including Design,
• OneWirelessTM Infrastructure Engineering & Commissioning
• Project management
• Lifecycle support services & training

One Honeywell Integrated Fire & Gas Solution
Integrated Control • Experion (DCS)

• Safety Manager FGS ESD DCS
& Safety Solutions
(ESD, F&G & BMS) (P2P)
(ICSS)
• Gas & Flame Detectors BMS IEC61511
F&G Solution
FAS IND
• FAS SEC
GAS
Integrated F&G • Addressable devices Smoke
and Security (Smoke & Heat Detectors)

Heat Flame
• Digital Video Manager
Solutions (ISS) (DVM)
NFPA/EN/BS/ATEX


Area 1 Safe-Net
Area 2
ESD & FGS
FTE
Fire-Net
FAS
Area 4 Area 3
Honeywell Integrated Unified Solution

Honeywell Fully Integrated Solution:
• 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)

• 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.

Fire & Gas and DVM Integration
Display Video of Alarm Recording Video of Alarm
EBI or Experion
EBI or Experion Stations
Server
DVM Clients DVM Database
and Camera Server
Local Area Network Video Network
Fire & Gas

System Camera Streamers
Digital Cameras
Analog Cameras
Alarm! Fixed or Pan, Tilt, Zoom
Cameras Supported
Alarm Activation from Detectors Cameras moves to the Alarm location

• Improve Operators Efficiency & Awareness
- Automated actions - Improve incident response time.
- Alarm video from Operator Station - Avoid unnecessary Shutdowns
27
SECTION
One Honeywell
2 Integrated Fire & Gas Solution
Fire & Gas and DVM Integration
• Integration is critical when every second counts.
Gas Leak Alarm Operator Clicks on Alarm

Triggered Associated PTZ Camera to Access Camera Page
automatically turn to the
alarm location
Experion PKS Displays Alarm video displayed on

the Alarm Automatic recording
dedicated station monitor
started

28
Agenda
- Summary and Q&A

29
KNPC - Kuwait
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
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.
30
KNPC - Kuwait
Honeywell Solution
This 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
Honeywell Confidentialrefinery
- © 2016 by Honeywell International Inc. All rights reserved.
31
KNPC - Kuwait
Block Diagram
CCR Safety Manager
Fire Station
XLS3000
ICSS Main FA Main FA HMI FGS HMI • Redundant Ethernet FO FTE
MFACP FGS ESD DCS
MCP
LFACP
Gas Detector
Flame Det.
Heat Det.
Horn/Strobe
• Dual Ring FO
- Modbus + XLS-Net
- Modbus
32
KNPC - Kuwait
Typical Architecture
Supervisory System
Experion PKS Operator DSA to other
Station EPKS Servers
Fault-Tolerant Ethernet
MFACP ESD
(Safety Manager) Safety System
4-20 ma Devices
SFACP Fire Water Pump Control

(XLS) Deluge Valve Control
Common Alarm to ECCC / CCR
KNUS GLASSET
TRYKK HER PRESS HERE
BREAK GLASS
Gas detectors Sounders & beacons

Fire detectors
33
Agenda
- Summary and Q&A

Traditional Field Wiring & Marshalling
Junction Junction Marshalling Safety Manager
boxes box Cabinet
DI
AI
DO
AO
DI
AI
DO
AO Multi
Core
Cables
DI
AI
DO
AO
System Integration Cables

Soft Marshalling – Reinventing field wiring
Fiber optic
Fiber optic
Fiber optic

Honeywell´s industrial F&G solution
Fire & Gas Controller – Safety Manager & Remote I/O
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
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

Fire & Gas Controller – Safety Manager & Remote I/O
 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
One I/O module instead of 4 different module types

Safety Manager Remote I/O – Fire & Gas
 Remote I/O supports typical F&G equipment

like:
• Gas-detectors
• Fire-detectors
• Smoke / Heat detectors
• Sounders
• Beacons
AI
DO
DO
DI
DI
AI
AI
• Etc.
 Supports AI, AO, DI and DO signals on any

channel
 Channel definition through application
programming

Multi Vendor Interface Program (MVIP)
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

Fire Alarm Panel

 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.

41

FAAST (Fire Alarm Aspiration Sensing Technology) - HSSD
 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
Second Stage Filter First Stage Filter
 Modbus Communication (DCS & ESD)
 7 Sensitivity levels with 3 years filter,
Dual laser detection Chamber

42
Pinnacle Detector (Laser-Ultra high Sensitive)

 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,

43
Smart Detectors
 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
SMART2 SMART³ SMART4

• Optical smoke detection • Optical smoke detection • Optical smoke detection
• Thermal detection • Thermal detection • Thermal detection
• Infra-Red flame detection • Infra-Red flame detection
• Carbon monoxide detection
Early Detection Without False Alarm

44
Inputs Outputs
Public Address Voice Alarm (PAVA)
• Smart Tool for Alarming and Orderly Safely People Evacuation
in the shortest possible time during emergency situations VARIODYN®
D1
• Only13% of people react in a timely manner to a tone alarms,
VAPA System
Headend
While
• 75% of people react to a voice message explaining the nature
of the emergency
• 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

First Responder Display

 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

47
Agenda
- Summary and Q&A

Honeywell Fire & Gas System will provide:
 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

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
Q&A
Thanks,
Moataz Ziadi

Integrated Fire and Gas Solution For People and Plant Safety

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Honeywell Technology Summit Kuwait

INTEGRATED FIRE & GAS SOLUTIONS FOR PLANT &

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

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

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

Some statistics around industrial F&G

In 2012 & 2013, the total value

Safety incidents cost the

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

Need for Fire & Gas System

Reliable Fire & Gas System

Improve Plant Safety Improve Plant Reliability

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

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

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

International codes and standards

Installation Codes Product Standards

Federal Law 123 GOST

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

Following Codes and Standards is a legal obligation in many countries

Non- Process Area - Straightforward Maximum

At least 6” (15 cm)

At least 90“ (229 cm) ’

50' x 50’ 15’

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

Performance / Risk Assessment

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

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

Develop FGS Philosophy

FGS Zone Definition

Outcome of FGS Design workflow: Determine FGS

• Redundancy for Availability

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

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

What is Fire and Gas system

Alarm Lists & Alarm Display

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

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

Fire & Gas in an industrial facility

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

F&G for Non-Process Areas (4)

Protection Layers (Relief Valves etc.)

Emergency Shutdown System Prevention

Distributed Control System

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

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

Honeywell’s holistic approach to Fire & Gas

Fire Control Sensors Gas PAVA

EN + TOTAL FIRE &

Honeywell Process & Life Safety Solutions

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

Honeywell’s holistic approach to Fire & Gas

Consultation & FEED Design & Engineering

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

Honeywell one-stop shop F&G supplier

Human Interface Field Equipment

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

Integrated Control • Experion (DCS)

and Security (Smoke & Heat Detectors)

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

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

Honeywell Integrated Unified Solution

Honeywell Fully Integrated Solution: