2013 Honeywell Users Group Europe, Middle East and Africa. Erik de Groot. Safety and Fire & Gas Solutions
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1 2013 Honeywell Users Group Europe, Middle East and Africa Erik de Groot Safety and Fire & Gas Solutions 1
2 Layered safety approach Emergency shutdown Burner management Fire and Gas 2
3 Out of the box Safety Safety Manager is TUV SIL 3 certified according IEC61508/ISA S84 I/O families to suit your requirements: Chassis I/O Universal Safety I/O Centralized and/or distributed applications Modify / update your application while production continues (TUV approved) Application changes Hardware changes Hardware additions Release migrations 4 Safety Manager SIL 3 out of the box
4 SAFETY MANAGER A.R.T. SAFETY MANAGER A.R.T. REDUNDANT CHASSIS IO SAFETY MANAGER A.R.T. REDUNDANT CHASSIS IO Supported hardware architectures Hardware Architectures Non-redundant Redundant Advanced Redundancy Technique Providing Safety, Availability, and Reliability SAFETY MANAGER A.R.T. 5
5 Universal Safety I/O High density 32 channel Universal I/O module Non-redundant or redundant Support of AI, AO, DI and DO signals on any channel Two wire termination plus three wire option Standard line monitoring 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 6 Flexibility meeting project need
6 Distributed Safeguarding UNIVERSAL Safety Logic Solver SIL 3 Universal I/O technology with: Function Logic Diagram execution Allows distribution of safety application Lower cost Increased availability of EUC Application transparency Fast execution cycle ( 60 msec) RUSLS cycle RUSLS cycle RUSLS cycle RUSLS cycle QPP cycle QPP cycle 7 Providing more flexibility and process availability
7 Distributed or Localized Safeguarding Ideally suited for: UNIVERSAL Safety Logic Solver Small equipment units Well head applications or pipeline control, or other distributed applications Continued safeguarding Even in the event communications to the Safety Manager are interrupted. Same spec and tech and topology guidelines 8
8 Lower TCO with Universal Safety I/O CAPEX Savings Reduce or eliminate the need for: Unique I/O modules External field power Junction boxes, marshalling cabinets, field auxiliary room Home run cables. cable ducts and infrastructure Expansions do not require additional multi core cables Reduced OPEX Savings Inter connections Test time Maintenance cost Dedicated I/O modules Increased Project efficiency Standard cabinets 9
9 (S)NTP PTP C200 (S)NTP PTP C200 CF-9 CF-9 SM-C300 P2P over FTE SM-C300 P2P SafeNet P2P over segregated Network SafeNet P2P over segregated Network Modbus TCP Modbus TCP Network flexibility Safety Manager supports Applications Experi on Server Icon Safety Station FTE Fully integrated network topologies Reduced infrastructure cost C300 Controller Safety Manager Safety Manager Other device Universal Safety I/O Fully segregated network topologies Providing maximum security, availability and reliability Applications Experion Server FTE Safety Manager Other device C300 Controller Safety Manager Separated Safety network Safety Station Universal Safety I/O 10 Safe, Secure Networking regardless of implementation
10 Operational Integration Two supported integration methods Experion SCADA Integration Continued support Advanced Experion Integration Ease of engineering and maintenance Console station support CEE peer-to-peer communication HMI Data access Integrated Alarm Notifications Experion Unified operator interface with simplified engineering and maintenance 11
11 Safe HART Field Device Support Universal Safety I/O HART Pass thru to FDM High performance, Safety Manager optimized communication Safety lock prevents: Inadvertent device changes Simple FDM device tree configuration Experion HART device alerts via MUX Monitoring Field Device Manager 12
12 Safety Manager New Functionality R151.1 Released end February 2013 Main added features Modbus Master (TCP/IP) Automatic cold start USI Module enhancements 13
13 Modbus Master Network: ModbusTCP RTU via gateway Dedicated Ethernet Redundant communication Both Safety Manager processors communicate with device Data is checked and synchronized between the processors One Modbus Master protocol per USI Max. 32 logical links per USI Including Safety Builder, PlantScape, CDA and Modbus Support for DI/DO via bit offset in word 14
14 Modbus Topology (Single) Experion Server Icon Safety Station FTE Slave or Gateway with single interface and one IP-address Separate TCP-connections (Device specific) Redundant communication 15
15 Modbus Topology (Redundant) Experion Server Icon Safety Station FTE Slave or Gateway with Redundant interface and two IP-addresses Separate TCP-connections Redundant communication 16
16 Configuration device options Modbus Slave Modbus Gateway 17
17 Application example Logical connection PLC address: Function code: Register: offset 18
18 Cold start-up Configurable per Safety Manager Controller Automatic start and transition to run after a power dip All variables are initialized (cold) 19
19 USI Module enhancements Support second SOE collector in combination with Universal Safety I/O Safety Historian via Serial com channel. Ethernet channel. DCS writes optimization Fast marker write Allows writing of all markers per cycle per protocol 20
20 Use case: Brownfield Type: Refinery revamp project Where: One of the larger refineries in the Netherlands Objective: Complete replacement of obsolete Safety Solutions Application: BMS and ESD applications Reason: Customer was facing obsolescence and resource problems (inadequate service response) Compliance to Safety standards and Compliance to cyber security standards (required by company, local authority and insurance policies) 21
21 Brownfield Safety solution revamp project Scope: Replacement of: Relay based Safety solutions (30++) Hardwired Safety solutions Upgrade of Honeywell TPS to Experion HMI Duration: Phased replacement over approx. 15 years First phase currently being executed FAT successfully completed Delivered: 3 Safety Manager systems (1800 I/O) including RUSIO and RUSLS 22
22 Brownfield Safety solution revamp project Why was Universal Safety I/O used? Universal characteristics and ease of change: Old field equipment uses amplifiers via trip-contacts and will be modernized and replaced within 3 years, Universal Safety I/O allows an easy change from DI to AI, via an On Line Modification the signal type of the channel can be changed without the need of rewiring or HW replacement. Local execution and safeguarding Universal Logic Solver is used for an application which required fast execution and required isolation of the main system Key advantages: Latest technology with good integration into Experion HMI Ease of change during modernization project HART pass-through capabilities 23
23 Our Fire & Gas Offering Fire & Gas System Experion HMI Fire Alarm Panels Flame and Smoke Detectors Toxic Gas Detection Camera Systems Sounders, Beacons 24 Most Comprehensive F&G Sensing Portfolio in the Industry
24 Maximize value and reduce costs Proven in use, fully tested and certified Standard design & solutions Improve overall system performance, enhance system diagnostics Reduce engineering and maintenance cost Seamless Integration with ESD/DCS No need for additional equipment or engineering Integrated solutions driving engineering, execution and operation efficiencies Provide a safe landing in case of emergencies 25 On-time startup
25 Maximize value and reduce costs One Shop Stop for Process and Non- Process Fire & Gas World class products, pre-tested, seamlessly integrated From FEED to After market services Design, Implementation, Maintenance, Upgrades Competent resources and execution/delivery excellence ensuring on-time startup Improved productivity Remote engineering, operations and maintenance tools Products and applications are designed to reduce false alarms 26 On-time startup
26 Use case: Green field Type: Natural Gas project producing up to 1 billion cubic feet of gas a day Where: Middle East Objective: New ICSS, using state of the art DCS and Safety technology Application: ESD, Fire and Gas, HIPPS Status: FAT finalized Q SAT scheduled for September 2013 ESD Field Devices Start up and full production capacity scheduled for Q2-Q Experion Server Experio n Station FTE Substation Hardwired I/O SafeNet/SB Network FTE Console Panel ESD Workstation Remote I/O IRP ESD/BMS/HIPPS Safety Manager ESD Workstation ESD/BMS/HIPPS SafeNet FGS Safety Manager MCB IES ESD Safety Manager 27
27 Green field: Mega Natural Gas project Size: Experion PKS HMI and Control, Universal Safety I/O & Honeywell Gas detection Technology Total DCS I/O: Total Safety I/O: Safety Manager systems (all safety networked) Universal Safety I/O count: (50 redundant universal Safety I/O modules) Why was Universal Safety I/O used? MCC located in separate building some distance away (significant savings on expensive long distance field cabling and infrastructure) Fire and Gas remote from the equipment rooms (substations) 28
28 Safety Manager R160 / FSC R800 Main Functionality Safety Manager connection to the EUCN; TÜV certified Fail Safe communication between FSC and Safety Manager. TÜV certified application migration tool for migration of FSC to Safety Manager Hardware migration kit to replace FSC Central Parts with Safety Manager controller chassis Use cases FSC based customers with TPN who want to extend their process unit(s) with EUCN; FSC based customers with Modbus connection to 3rd party DCS who want to extend their process unit(s) The control and safety system lifecycle planning needs to support the production facility beyond 2025 The wish to use new functions and features not supported on FSC 30
29 The Next Evolution Path What is NEW Protect your intellectual property by migrating your FSC system to the 21 st Century safeguarding technology: Extend the lifetime of your safeguarding system Introduce the latest safety features Prevent a rip and replace Maintain all your field wiring and devices Maintain the safety application Limit training for maintenance and engineering staff 31 Revolutionary Technology Delivered in an Evolutionary Way
30 Safety Manager on EUCN 1 st part Total Plant Solution Expand your process units with Safety Manager LCN Fault Tolerant Ethernet NIM ENIM UCN EHPM FSC SM EUCN / FTE 32 Revolutionary Technology Delivered in an Evolutionary Way
31 SafeNet between FSC & Safety Manager 1 st part Experion FTE FSC R7xx FSC R7xx Experion PKS Expand your process units with Safety Manager and Experion SCADA SM R160 FSC R7xx SM R160 Fault Tolerant Ethernet FSC R800 FSC-FSC (serial) FSC-SM (serial) SAFENET (Ethernet) RIOLINK (Ethernet/F.O.) 33 Revolutionary Technology Delivered in an Evolutionary Way
32 Hardware migration to Safety Manager 2 nd part FSC with Native I/O Safety Manager with Native I/O Hardware Migration Kit(s) Maintain your IO modules, field instruments and wiring and obtain the 21 st Century safety features Universal Safety IO with Hart pass through 34 Revolutionary Technology Delivered in an Evolutionary Way
33 Hardware migration to Safety Manager 2 nd part FSC with Safety Manager I/O Safety Manager with Safety Manager I/O Hardware Migration Kit(s) Maintain your IO modules, field instruments and wiring and obtain the 21 st Century safety features ISA secure 35 Revolutionary Technology Delivered in an Evolutionary Way
34 Software migration to Safety Manager 2 nd part TÜV approved application migration tool Maintain your application & save test time and training of maintenance & engineering personal TÜV Approved Verification 36 Revolutionary Technology Delivered in an Evolutionary Way
35 Phased Migration Possibilities SM LCN Fault Tolerant Ethernet NIM ENIM UCN EHPM C300 FSC EUCN / FTE 37 Revolutionary Technology Delivered in an Evolutionary Way
36 Migration Strategy Plan Today Global Migration Core Team Near Future Safety Audit Evaluates and reports the current situation Configuration, application, Networking, Hardware, software, and more Migration Strategy and Plan Define a strategy Impact analysis, cost, how, when, detailed scheduling Migration Execution (Phased) Execute the migration This may be a phased migration covering several years 38 Revolutionary Technology Delivered in an Evolutionary Way
37 40
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