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Presented to

Our Valued Client

Agenda

Introduction AE Solutions Key Personnel Traditional Independent Fire and Gas Solutions AE Solutions SI-FGS History Definition of a Safety Instrumented Fire & Gas System (SI-FGS) Integrated SI-FGS Features

FGS 1400 System


COTS Technology Cost Effective / Scaleable Facility-Wide Networking FM Approved

FGS Detection Insights MicroPack CCTV Video


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Copyright AE Solutions 2006

Brian Merriman

President & Operations Manager of AE Solutions BS degrees in Mechanical and Agricultural Engineering Registered Professional Engineer Held technical, sales, marketing and executive positions with Engineering Companies and System Integrator Member of ISA and NFPA Presenter at technical conferences and user seminars on Safety Lifecycle Execution

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Mike Scott PE, CFSE


VP, Process Safety with AE Solutions BS and Masters Degrees in Mechanical Engineering Registered Professional Engineer in SC,GA,IL & AK Certified Functional Safety Expert (CFSE) Member CFSE Governance Board Author of numerous technical papers related to process safety Member of ISA and AIChE ISA Course Developer / Instructor

SI-BMS Webinar SI-FGS Webinar SI-BMS Class BMS Subcommittee co-chair FGS Subcommittee co-chair

ISA SP84 Committee Member


ISA Safety Division BMS Subcommittee chair

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Ken OMalley PE, CFSE


VP Operations of AE Solutions BS degree in Electrical Engineering Registered Professional Engineer Certified Functional Safety Expert (CFSE) Held technical and executive positions with Engineering Companies and System Integrator Member of ISA and NFPA Project Manager & Engineer for Process Safety Projects Developer of FGS 1100 & Project Sponsor for SI-FGS Technology Conversion to FGS 1400.

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Warren Johnson

Principal Control System Specialist FGS Project Manager BS Electrical Engineering Registered Professional Engineer

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Conventional Fire Panel Plus Separate SIS, Gas Detection, HVAC Control, etc.

High Cost of Ownership !!!


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The Conventional Way


HMI DC S
H MI

EW S

Fire HVAC &/or BPCS Control Fire I/O HVAC I/O

Gas &/or SIS

EW S

Gas I/O

Platform A

Platform B &/or C

Platform D &/or E

FGS with Traditional Fire Panel & Gas PLC


Required Elements

Base Fire System Cost for 50 I/O & Suppression Separate dedicated PLC system for Gas Monitoring for 30 I/O Dedicated HVAC Control Panel by Vendor Retransmit Cost I/O 100 Points or Multiple Communication Links to DCS for Logging, Display and Trending I/O Interface Between Multiple Systems to Coordinate Control of Valves, HVAC Units, Exhaust Fans, Suppression Devices Multiple Engineering Workstations, Software Licenses, Training Multiple Operator Platforms w/ Training Multiple Maintenance Platforms w/ Training, Spares, Procedures Multiple Vendor Interfaces and Coordination Complex System Integration

FGS1400 includes all functionality in single FM approved system


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Safety Instrumented Fire & Gas Systems


from

AE Solutions

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Safety Instrumented Fire & Gas Systems from AE Solutions (SI-FGS)

Definition of a Safety Instrumented Fire & Gas System (SI-FGS) AE Solutions SI-FGS History Integrated SI-FGS Features

FGS 1400 System


COTS Technology Cost Effective / Scaleable Facility-Wide Networking FM Approved

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Safety-Instrumented Fire & Gas System (SI-FGS)


System comprised of initiating device sensors, logic solvers, final control elements, fire safety functions and / or notification appliances for the purpose of mitigating an event when predetermined conditions are violated.

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Safety-Instrumented Fire & Gas System (SI-FGS)


Proprietary Supervisory Station

PCS7 / Safety Matrix Engr Console

NFPA 72 Considerations

Prescriptive in nature

Provides the minimum set of requirements Use of listed devices Specific architecture Primary & Secondary power supplies Installation, test and maintenance procedures Statement of compliance from an authorized body Integrity checking of:

Mandates

Initiating Devices Notification Devices Control Devices System Wiring


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Industry Update
ANSI / S84 Application of Safety Instrumented Systems for the Process Industries
Developing a guidance document on application of Safety Lifecycle concepts to FGSs

Fire Protection Handbook Vol II, 19th Edition


Provides guidance on reliability calcs for FGS

SINTEF STF38 A02420 Reliability Prediction Method for Safety Instrumented Systems
Contains guidance for performance based gas detection system

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Combination System SIF Included in FGS

FGS Capable of SIL 3 Safety Instrumented Function (SIF) Implementation Can Integrate:

Safety Instrumented Functions


HVAC Control Exhaust Fan Control

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Safety-Instrumented Fire & Gas System


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CP Requirements for FGS1100


Common Safety PLC for Fire, Gas, HVAC & Miscellaneous Controls Fire Marshall 3rd Party Approval to NFPA 72 Gas Approvals for

Combustible Gas Std 6320 Toxic Gas Std 6340 ANSI/ISA 12.13.01

Common HMI Easy integration with BPCS Common Components Processor Redundancy Option Monitored I/O Circuits Energize-To-Trip Outputs 24-Hour Battery Backup System Possibility for Extended Test Intervals
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Additional Requirements for FGS1400

Based on same Platform as Planned BPCS & SIS Upgrades and Expansion Projects Remote I/O option to minimize installation costs Ethernet Communications for Enhanced Networkability & Extended Premise Latest Available Architecture from Siemens Commercial Off-The-Shelf Technology (COTS)

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SI-FGS History

FGS 1100

FGS 1400

Based on Siemens Quadlog platform Fire & Gas Integration Designed for CP Available June, 2004 FM Approved Installed at Kuparuk and operational since December, 2004

Based on Siemens Latest PLC Technology Supports Remote I/O Combination System Extremely Scalable Large Scale Networking Supervising Station FM Approved Available Q1, 2006

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Safety-Instrumented Fire & Gas System


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Typical FGS 1400 Fire & Gas System


Proprietary Supervisory Station

PCS7 / Safety Matrix Engr Console

FGS1400 Protected Premise


ES

Local First Responder Interface FGS 1400 Fire & Gas System

Remote I/O Local I/O Fire, Gas, SIS or HVAC I/O Fire, Gas, SIS or HVAC I/O

Remote I/O

Fire, Gas, SIS or HVAC I/O

Features of The FGS 1400

A cost-effective turnkey FGS Solution Based on Commercial Off The Shelf Technology (COTS) FGS 1400 is comprised of the Fire Alarm Panel, the Battery Charger Panel and the Battery Set FM Approved for Both Fire & Gas Detection and SIS functions within the Same PLC in Compliance with the Interference-Free Combination System paragraph of NFPA 72 Designed to Levels of Reliability and Availability Commensurate with National Safety Standards for Safety Instrumented Systems (SIS) Highly Scalable Solution, 50 to 50,000 I/O
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Features of The FGS 1400

Includes Interface Capability to a Wide Variety of Sensors and Final Control Elements Simple Touch Pad or Optional PCS 7 Based Local First Responder Interface with Graphics Capable Display Developed around the Siemens Simatic S7-400F SIL3 Certified Safety PLC Platform Communication to Other Control Systems via Hardwired Industrial Ethernet, Profibus I/O or Modbus Powerful Engineering Station / HMI

Siemens PCS-7 Siemens Safety Matrix

Cause & Effect Interlock Configuration & Display for Fire & Gas Detection / Suppression System

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FGS 1400 System I/O Circuits

Both analog & discrete Class B, Style A Initiating Device Circuits (IDC)

Up to 20 digital devices per circuit

NFPA 72 Class B, Style W Notification Appliance Circuits (NAC)

Up to 10 Amps per circuit

Both energize-to-trip and de-energize-totrip Fire Safety Functions (FSF) Suppression Device Circuits (SDC)

2 Amps per circuit

Meets Integrity Monitoring requirements of NFPA 72


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Local Touch Panel First Responder Interface

Color Graphics LCD on the Fire Panel Displays System Status and Diagnostic Information Fire Alarm Zone Monitoring Active and Historical Alarm Lists Siemens Hardened Touch Panel (TP270) WinCC Flexible Application
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Optional - Local PCS7 First Responder Interface


Color Graphics HMI on the Fire Panel Displays System Status and Diagnostic Information Fire Alarm Zone Monitoring Active and Historical Alarm Lists Safety Matrix Viewer Siemens Hardened Industrial PC Integrated PCS7 HMI Application
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Engineering Station (ES)

Implemented Using Siemens Safety Matrix Configuration and Monitoring Software Located Anywhere on Ethernet Network Functionality includes:

Automated System Cause & Effect Configuration Methodology Operational HMI for System Monitoring Bypassing Capability for Troubleshooting, Maintenance & Testing
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Battery Back-Up System


Meets all NFPA 72 Requirements for 24 Hour Battery Supply 120 VAC System Input Battery Charger 24 VDC to Fire Circuits with Ground Fault Detection DC / DC Converter for Regulated 24 VDC for Other Components Individual Alarm Outputs to the Processor for: AC Power Failure Battery Charge Level Charger Health
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Battery Back-Up System


Battery Charger Panel

Typical Battery Bank

The FGS1400

FGS 1400 Scalability


Local & Remote I/O, Redundant Controller, PCS7 First Responder HMI Local I/O, Simplex Controller, PCS7 First Responder HMI
Systembus

Local I/O, Redundant Controller, WinCC Flex First Responder HMI

Industrial Ethernet / Fast Ethernet First Responder Interface

AS 414 FH AS 417 FH ET 200M


Fail-Safe PROFIBUS-DP

AS 414 FH AS 417 FH
PROFIBUS-DP

ET 200M
Fail-Safe

ET 200M
Fail-Safe

ET 200M
Fail-Safe

ET 200M
Fail-Safe

ET 200M
Fail-Safe PROFIBUS-DP GLASS FIBER

Small Scale Simplex FGS 1400

OLM

Remote I/O Panel ET 200M


Fail-Safe

FGS 1400 Simple Architectures


Remote or Local Engineering Station (1 Required)
PCS7 ES w/ Safety Matrix Tool

Proprietary Supervision Station

Remote or Local Monitoring Station

PCS7 OS Single Station w/ Safety Matrix Viewer & Dual Monitor

PCS7 OS Single Station w/ Safety Matrix Viewer

Systembus FGS 1400 AS 414 FH AS 417 FH FGS 1400 AS 414 F AS 417 F

Industrial Ethernet / Fast Ethernet FGS 1400 AS 414 FH AS 417 FH

WinCC Flex Touchpanel FRI, Redundant Controller

WinCC Flex Touchpanel FRI, Simplex Controller

PCS 7 PC Based FRI, Redundant Controller

FGS 1400 HMI Architectures


Client - Server Architecture
Operator Terminals (1...16) Remote or Local Engineering Station (1 Required) Terminalbus Ethernet

Remote or Local Single Stations (As Required)

OS-Server (1...6)
Engineering Station (ES) Systembus FGS 1400 AS 414 FH AS 417 FH FGS 1400 AS 414 FH AS 417 FH Industrial Ethernet / Fast Ethernet FGS 1400 AS 414 FH AS 417 FH

Completely Integrated Architecture


Manned Control Center
Operator Terminals (1...16) Terminalbus Engineering Station ES Systembus Fire & Gas (FGS1400) AS 414 FH AS 417 FH
PROFIBUS-DP

ERP Ethernet

MES

PCS 7 @ Warehouse Ethernet OS-Server (1...6) OS Single system

Industrial Ethernet / Fast Ethernet Process Safety (SIS) AS 414 FH AS 417 FH Process Control (BPCS) AS 414 FH AS 417 FH ET 200M
Fail-Safe PROFIBUS-DP

First Responder Interface


PROFIBUS-DP GLASS FIBER

ET 200M
Fail-Safe

ET 200M Y-Link

ET 200M
Fail-Safe

OLM

Remote I/O Panel ET 200M


Fail-Safe

ET 2a00M
Fail-Safe

ET 200M
Fail-Safe

DP/PALink

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Distribution and Effectiveness aspects of fire and gas detector placement

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SI-FGS Terms
Geographic Detector Coverage

Is defined as the fraction of process area where - if a fire of defined size / volume occurs the event is detectable by a given sensor placement array (and voting logic if automatic process actions are required)

e.g. - 90% probability that 2ooN fire detectors will be capable of sensing a given fire of a given intensity (e.g. 10 KW)

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SI-FGS Terms
Scenario Detector Coverage
Is defined as the fraction of fire hazard scenarios that are detectable by a given sensor placement array (and voting logic if automatic process actions are required)

e.g. - 90% probability that a fire hazard of given intensity (e.g. 10 KW) will be detected by 2ooN fire detectors for a given hazard scenario (e.g. flange fire)

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SI-FGS Terms
FGS Effectiveness The Probability of Failure on Demand (PFDavg ) associated with the FGS Safety Instrumented Function

This is the traditional PFDavg component calculated for sensors / logic solver / and final elements for a given architecture and test interval SIL target defined for the Fire Safety Functions

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SI-FGS Terms
Mitigation Effectiveness The probability that the actions of the final elements prevent small fire or accumulation from escalating to a large fire or accumulation.

Examples of where the mitigation action may not be 100% effective are as follows:

Deluge does not completely put out the fire Isolation and / or bleed of pressure from the system is not fast enough to prevent the accumulation due to the leak from reaching the large catastrophic cloud size. Etc.
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SI-FGS Concepts
Detection Coverage (0.90) S1 Gas Leak occurs (x/yr)

FGS Effectiveness S2 F2
(0.05) (0.95)

Mitigation Effectiveness S3 F3 (0.20) (0.80) $ $$$ $$$

F1 (0.10)

$$$

S1* S2* S3 = effectiveness of Gas Detector System

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CCTV Fire Monitoring Systems


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Micropack Interface Simplified Connection Diagram

Camera video displayed automatically when Detector selected by Operator

Alarms

HMI

Camera Selection

Fire & Gas System

Alarms

IP Video Streamin g via Ethernet

Transmitters
Analog & Digital Hardwired

Micropack Fire & Gas Camera Control System System


Modbus Serial link

Video Cameras Video

FGS 1400 Supervising Station

Video Jet Video Jet Video Jet Video Jet

Design Based on Saturn for Cavendish One Hub Controller Required Per 12 Visual Flame Detectors

TCP/IP Network

RS 485 Modbus FGS 1400 Controller 4-20mA

Hub controller

Video Switcher

TERMINALS
1TO 12 DETECTORS

Micropack Lap top For commissioning only

This set up allows FGS 1400 to select and display video from the Micropack cameras on the FGS Supervising Station

The FDS-101
An Imaging Based Flame Detector

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Fire & Gas Detection


Mapping

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Typical Fire Detection Targets


Typical Offshore Platform
Fire Size (RHO) Control Action 10kW 50kW 250kW Grade A B C S Alarm 10kW 10kW 100kW

Defined By Hazard

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Study Methodology
1. Prepare performance targets 2. Collect applicable drawings of equipment installation 3. Survey the areas of interests w/ digital photographs 4. Assess the performance of existing detection using custom software 5. Identity gaps between actual and required performance 6. Propose measures to close these gaps
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Mapping Software
The software that implements guidance is Micropacks FDA and GDA custom software package. The process starts by converting a detector field of view picture into a 2 D software footprint taking account all obstructions shown in the photograph. This footprint is overlaid onto a graded equipment layout

The resulting coverage is assessed using the performance targets.


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Grade Maps & Assessments


Notes : (Detection Scenarios) 1. 2. The control and alarm target fires can be 'seen' by the flame detection system Because the Grade B detection target requires an alarm to a smaller fire size it is possible for two detectors to respond to the 50Kw control action target while being unable to respond to a smaller 10Kw alarm fire target. This case occurs when only one detector can 'see' the fire - two detectors are required for control action. This case occurs when the detector is too far from the hazards to 'see' the specified target fire size. If the fire incident escalated then the detector will respond No detector can see this hazard and there will be no response.

3.

4.

5.

Test Ground Grade Map


The vessels are all grade B

This the Ex test ground with the vessels graded

Test Ground FD1


Detector 1

with No Obstructions

Test Ground FD2


Detector 2 with No Obstructions

Test Ground Assess 1


This is the areas assessment with no obstructions interfering with the FD1 field of view.

Notice Very High Level of Coverage

Test Ground FD1a


Detector 1 With Obstructions

Test Ground FD2a


Detector 2 With Obstructions

Test Ground Assess 2


This is the areas assessment with obstructions shown interfering with the detectors field of view.

Notice very poor level of coverage

Gas Detection Methodology


Process Areas
1. 2.

Specify category of Risk Volume (Open, Enclosed, Congested) Specify dimensions of Explosion Hazard - Assume Stochiometric Gas/Air mix Assess existing detection coverage

3.

4.

If required, design detector layout to detect (2) above

Non-Hazardous Area Air Intakes


1. 2.

Establish Transit Time from the intake to the nearest potential ignition source Detector / HVAC closure response time to be less than (1) above

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GDA Grade Map (6m)

GDA Assessment (6m)

Smoke & Heat Detection


Assessed against NFPA 72
Detector spacing Ceiling Height Air change rate

Air Movement Study

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Comprehensive Survey Report


Details

of each area reviewed including:

Area Description/Hazards/Performance Targets Existing Detection

FDA

and GDA Assessments. Summary of all recommendations

Detector Additions / Deletions / Relocations

CAD

Layout Drawings

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Thank You!

Are There Any

Applied Engineering Solutions, Inc.


www.aesolns.com