Safety System Lifecycle Support with Safety Manager and Fire & Gas Update

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


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


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


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


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


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


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


2nd Half 2015

Off-process 2014

Industrial Fire & Gas Solutions

Jeff Kuhn, HPS Americas Fire and Gas COE


• 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


• 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


F&G in an Industrial Facility


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


Honeywell – One Stop Shop in F&G


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


Honeywell´s new F&G controller


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


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


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


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


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


Flexible F&G Networking


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


F&G Solutions – Where do you find us?