Honeywell System 57 Gas Detection Control System: Comprehensive Overview

Honeywell System 57 Gas Detection Control System: Comprehensive Overview

The Honeywell System 57 is a highly versatile, reliable, and intelligent gas detection control platform designed to safeguard personnel, facilities, and processes from the hazards of toxic, combustible, and oxygen deficiency/enrichment gases. Engineered with Honeywell’s decades of expertise in gas sensing and control technology, the System 57 provides centralized monitoring, alarming, and data logging capabilities, making it an ideal choice for a wide range of industrial and commercial applications where gas safety is paramount.

Key System Features & Advantages:

• Modular and Scalable Architecture: Easily expandable to accommodate varying numbers of gas detectors and input/output requirements.

• Advanced Sensor Compatibility: Supports a wide array of Honeywell gas sensors, including electrochemical, catalytic bead, infrared (IR), and photoionization detectors (PIDs).

• Intuitive User Interface: Features clear, graphical displays with menu-driven navigation for easy configuration, operation, and status monitoring.

• Comprehensive Alarm Management: Multiple programmable alarm levels (low, high, fault) with configurable relay outputs for audible/visual alarms, ventilation control, or process shutdown.

• Robust Data Logging and Communication: Capable of storing historical event and concentration data, with options for serial (RS-485 Modbus) or Ethernet communication for integration with building management systems (BMS) or distributed control systems (DCS).

• High Reliability and Diagnostics: Built-in self-diagnostics and sensor health monitoring to ensure system integrity and minimize downtime.

• Global Compliance: Designed to meet various international safety standards and certifications.

Representative Product Models and Parameters

The System 57 family comprises several controller models and a vast range of compatible gas detectors. Below are some key examples:

1. Control Units:

• Model 57C-I-4/8/16 (Standard Control Unit)

• Input Channels: 4, 8, or 16 (configurable for 4-20mA or digital RS-485 Modbus sensors)

• Display: 128 x 64 graphical LCD with backlight

• Relay Outputs: 8 programmable Form C relays (common for alarm levels 1 & 2, fault, and system fault; expansion options available)

• Communication: RS-485 Modbus RTU (standard), optional Ethernet Modbus TCP

• Power Supply: 85-265 VAC, 50/60 Hz or 24 VDC

• Operating Temperature: -20°C to +50°C (-4°F to +122°F)

• Enclosure Rating: NEMA 4X / IP66 (wall-mount)

• Certifications: CE, ATEX, IECEx, UL/CSA (varies by configuration)

• Description: The core controller, available in 4, 8, or 16 channel configurations to interface with multiple gas detectors.

• Key Parameters:

• Model 57C-R-4/8/16 (Remote Display Unit)

• Display: Same as 57C-I, mirroring primary controller data.

• Communication: RS-485 Modbus RTU to primary controller.

• User Inputs: Alarm Acknowledge, Silence (configurable).

• Enclosure Rating: NEMA 4X / IP66 (wall-mount)

• Description: A secondary display unit that can be networked to a primary 57C controller to provide remote status indication and alarm acknowledgement.

• Key Parameters:

2. Gas Detectors (Transmitters) Compatible with System 57:

• Honeywell Searchpoint Optima Plus (Infrared Combustible Gas Detector)

• Detection Principle: Non-Dispersive Infrared (NDIR)

• Gases Detected: Methane (CH4), Propane (C3H8), Ethylene (C2H4), and others (calibration specific)

• Measuring Range: 0-100% LEL (Lower Explosive Limit)

• Output: 4-20mA linear, HART (optional), RS-485 Modbus (optional)

• Response Time: < 5 seconds (T90)

• Accuracy: ± 2% of full scale or ± 3% LEL (whichever is greater)

• Operating Temperature: -40°C to +75°C (-40°F to +167°F)

• Enclosure Rating: IP66/67

• Certifications: ATEX, IECEx, FM, CSA

• Description: Highly reliable IR detector for methane and other hydrocarbons.

• Key Parameters:

• Honeywell Sensepoint XCD (Toxic and Oxygen Gas Detector)

• Detection Principle: Electrochemical (for toxic and O2)

• Gases Detected: Carbon Monoxide (CO), Hydrogen Sulfide (H2S), Oxygen (O2), Chlorine (Cl2), Ammonia (NH3), and many others (sensor specific)

• Measuring Range: Varies by gas (e.g., CO: 0-500 ppm, H2S: 0-100 ppm, O2: 0-25% vol)

• Output: 4-20mA linear, RS-485 Modbus (optional)

• Response Time: Typically < 30 seconds (T90) for toxic gases

• Accuracy: ± 5% of reading or ± 3% full scale (whichever is greater)

• Operating Temperature: -40°C to +55°C (-40°F to +131°F)

• Enclosure Rating: IP66

• Certifications: ATEX, IECEx, FM, CSA

• Description: Compact, robust detector for a wide range of toxic gases and oxygen.

• Key Parameters:

• Honeywell Impact Series (Portable Gas Detector - for comparison/complementary use)

• Gases Detected: Up to 4 gases simultaneously (e.g., LEL, O2, CO, H2S)

• Sensors: Catalytic bead (LEL), electrochemical (toxic/O2)

• Display: LCD with simultaneous gas readings

• Alarm: Audible (95dB), visual (LED), vibrating

• Battery Life: Up to 20 hours (alkaline), 12 hours (rechargeable)

• *Note: While System 57 is fixed, Honeywell’s portable Impact series are often used in conjunction for personal safety.*

• Description: Multi-gas portable detector for personal monitoring.

• Key Parameters (e.g., Impact Pro):

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.

Example 3: Underground Parking Garage

• Scenario: A large shopping mall has a multi-level underground parking garage that accommodates hundreds of vehicles. Carbon monoxide (CO) from vehicle exhaust can accumulate to dangerous levels if not properly ventilated.

• System 57 Application: A Honeywell 57C-I-12 controller is located in the building’s maintenance room. Multiple low-cost Sensepoint XCD CO detectors are distributed evenly across each parking level, typically near exhaust points and in low-lying areas where CO can accumulate.

• Operation: During peak shopping hours, vehicle traffic is high, and CO levels begin to rise in one section of the garage. The CO detectors monitor the ambient air and send continuous readings to the 57C controller. When the CO concentration reaches a preset low-alarm setpoint (e.g., 35 ppm), the controller triggers relays to start the exhaust ventilation fans for that specific level or zone. As CO levels decrease below the setpoint, the fans can be set to slow down or turn off (with a suitable delay), optimizing energy efficiency. If CO levels were to reach a dangerous high-alarm setpoint (e.g., 100 ppm), additional alarms could be triggered to alert building management and the public address system could be used to guide people away from the affected area. The system also logs CO trends for maintenance planning.

Conclusion

The Honeywell System 57 Gas Detection Control System is a comprehensive and reliable solution for mitigating gas-related risks across a broad spectrum of industries. Its modular design, extensive sensor compatibility, advanced alarm capabilities, and robust data management make it a trusted choice for ensuring safety, compliance, and operational efficiency. By providing early warning of hazardous gas conditions, the System 57 plays a crucial role in protecting lives, property, and the environment. For specific configurations, detailed sensor compatibility, and the most up-to-date specifications, it is always recommended to consult with Honeywell or authorized distributors.