Honeywell System 57 Gas Detection Control System: Comprehensive Overview

Application Scenarios

The Honeywell System 57 is designed to cater to diverse industries where gas hazards exist:

1. Oil & Gas Exploration and Production:

• Onshore/Offshore Platforms: Monitoring for combustible gases (methane, propane) in drilling rigs, production decks, living quarters, and control rooms.

• Refineries: Detecting toxic gases (H2S, benzene, CO) and combustible hydrocarbons in process units, storage tank farms, loading docks, and pipelines.

• Natural Gas Processing Plants: Monitoring for leaks in compressors, separators, dehydration units, and metering stations.

2. Chemical and Petrochemical Industry:

• Chemical Plants: Detecting a wide variety of toxic gases (chlorine, ammonia, hydrogen cyanide, VOCs) and combustible vapors in reactors, storage areas, loading bays, and wastewater treatment facilities.

• Petrochemical Complexes: Monitoring process streams, storage tanks, and transfer points for leaks of flammable and toxic chemicals.

3. Manufacturing and Industrial Processing:

• Semiconductor Fabrication: Monitoring for toxic gases (arsine, phosphine, silane) used in cleaning and etching processes.

• Automotive Plants: Detecting combustible gases (from painting, coating processes) and toxic gases (CO from forklifts, welding fumes).

• Food and Beverage Processing: Monitoring for CO2 (from fermentation), ammonia (from refrigeration), and oxygen deficiency in confined spaces.

• Power Generation: Monitoring for hydrogen (in generator cooling systems), combustible gases (in boiler rooms), and CO (from combustion processes).

4. Commercial and Institutional Buildings:

• Parking Garages: Monitoring for CO from vehicle exhaust to control ventilation fans.

• Boiler Rooms: Detecting combustible gas leaks (natural gas, propane) and CO.

• Laboratories: Monitoring for various toxic gases and oxygen depletion/enrichment.

• Hospitals: Monitoring for medical gases (e.g., oxygen, nitrous oxide) in storage and patient areas.

5. Water and Wastewater Treatment:

• Wastewater Treatment Plants: Detecting H2S, methane, and oxygen deficiency in sludge digesters, aeration basins, and confined spaces.

6. Mining and Tunnels:

• Underground Mines: Monitoring for methane (firedamp), CO (from diesel equipment), and oxygen deficiency.

• Tunnel Construction: Similar gas hazards as mines, plus potential for VOCs from machinery.

Real-World Examples

Example 1: Offshore Oil & Gas Platform

• Scenario: An offshore oil production platform operates in a harsh marine environment. There is a constant risk of hydrocarbon gas leaks from wellheads, separators, and pipelines. Personnel safety and asset protection are critical.

• System 57 Application: A central Honeywell 57C-I-16 controller is installed in the platform’s control room. It is connected to multiple Searchpoint Optima Plus IR detectors (for methane and propane LEL monitoring) and Sensepoint XCD electrochemical detectors (for H2S and CO) strategically located throughout the production deck, wellhead area, living quarters, and utility rooms.

• Operation: In the event of a gas leak (e.g., methane from a flange connection), the local detector rapidly senses the increasing gas concentration and transmits the signal to the 57C controller. The controller’s display shows the location and concentration. If the concentration exceeds the preset low-alarm threshold (e.g., 20% LEL), the controller activates audible/visual alarms locally and in the control room, and triggers relays to start ventilation fans in the affected area. If the concentration continues to rise to the high-alarm threshold (e.g., 50% LEL), additional relays are triggered to initiate emergency shutdown (ESD) sequences for critical equipment, preventing potential ignition and explosion. The event is logged for later analysis. Remote display units in key areas ensure personnel are always aware of gas status.

Example 2: Chemical Storage Tank Farm

• Scenario: A chemical distribution company stores large quantities of toxic and flammable chemicals (e.g., ammonia, chlorine, toluene) in aboveground storage tanks. Regulatory compliance and worker safety are top priorities.

• System 57 Application: A Honeywell 57C-I-8 controller is installed in the tank farm’s control shack. Sensepoint XCD detectors, each calibrated for a specific gas (ammonia, chlorine, toluene LEL), are mounted around the perimeter of each tank group and near loading/unloading stations.

• Operation: During the loading of an ammonia tanker truck, a hose connection fails, releasing ammonia vapor. The nearby ammonia detector quickly responds, sending a 4-20mA signal to the 57C controller. The controller identifies the gas type and location, activates the local alarm horn and strobe, and displays the concentration on its screen. The high-level alarm relay is triggered to automatically shut down the loading pump and actuate a water spray curtain to suppress the vapor cloud. Simultaneously, an alarm signal is transmitted via Modbus to the facility’s central security and BMS, alerting emergency response teams. The entire event, including time, date, gas concentration, and alarm status, is recorded in the controller’s data logger for regulatory reporting and incident investigation.