Submitted to the Electrical & Electronics Engineering Department in partial fulfilment of the requirements

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Optimizing Fire Detector Placement in Process Plant Using Boolean Techniques

By

MOHAMED ISMAIL KHALID MOHAMED 12921

for the Bachelor of Engineering (Hons) (Electrical

&

Electronics Engineering)

SEPTEMBER 20 II

Universiti Teknologi Petronas Bandar Seri Iskandar

31750 Tronoh Perak Darul Ridzuan

©

Copyright 20 II

By

MOHAMED ISMAIL KHALID MOHAMED

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CERTIFICATION OF APPROVAL

Optimizing Fire Detector Placement in Process Plant Using Boolean Techniques

Approved by:

By

MOHAMED ISMAIL KHALID MOHAMED

A project dissertation submitted to the Electrical & Electronics Engineering Programme

Universiti Teknologi PETRONAS in partial fulfilment of the requirement for the

Bachelor of Engineering (Hons) (Electrical & Electronics Engineering)

DR. VIJANTH SAGAYAN ASIRVADAM Associate Professor

Elot\lio::.lll & Electronic Engineering ilej)artment

~lti Telmologi PETRONAS

~n~ Tronon Perak

ltoJI: ros.l6a788t Fax: 05·3657443

UNIVERSITI TEKNOLOGI PETRONAS TRONOH, PERAK

SEPTEMBER 20 II

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CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the original work is my own except as specified in the references and acknowledgment, and that the original work contained herein have not been undertaken or done by unspecified sources or persons.

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ABSTRACT

In oil and gas industry, fire outbreak is one of the

main

accidents in onshore and offshore facilities. The damage caused by the fire could be minimal or extensive, hence the Fire and Gas Detection Systems are critical systems used to safeguard hazardous area in process plant. Such systems are installed to protect lives, enviromnent, monetary assets and reputation of the company. The main concern of fire detection system is to provide adequate number of detectors that scan through an enclose hydrocarbon processing area which consists of hazardous equipment. In reality, it may be impossible to build a fire detection system that cover the whole plant and detect all possible hazardous scenarios. Therefore, this project attempts to solve this problem and improve the fire detection system by developing software that will optimize the fire detectors location on 2.5 dimensions in order to find the optimum coverage that will achieve the desired level of protection taking into account Hazard Map. MAT ALB was used to develop the software based on Image Processing and Boolean Techniques. In fact, this project has valuable contribution and useful solution to oil and gas industries.

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ACKNOWLEDGMENT

First of all, my utmost gratitude is due to ALLAH the Almighty for his uncountable graces upon me and for the successful completion of this project. Then, my deepest heart gratitude goes to my parents who haven't hesitated to sacrifice anything to ensure my success in my academic journey and for their encouragement throughout my life.

Much respectful regards and appreciation are carried to my supervisor Assoc. Prof. Dr. Vijanth Sagayan Asirvadam for his great supervision, continuous support, precious guidance and understanding which truthfully help me throughout completing this project My gratitude is extended to Mr. Abdel Aziz Rasikh, Instrument Engineer at PETRONAS Carigali Sdn. Bhd. for his kind assistant in enhancing my technical knowledge about the topic and for his great guidance and friendly approach.

Lastly, great appreciation to all the lecturers of Electrical and Electronic Engineering Department for their advices and all my friends in Universiti Teknologi PETRONAS for their continuous help and experience sharing and to all people who their names are not mentioned here but they provided help to my success.

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TABLE OCONTENTS

CHAPTER 1 ... 1

PROJECT BACKGROUND ... I

1.1 INTRODUCTION •...•.••..•...•...•..••...••.••..•...••..•...•..•...•..•...••.. 1

1.2 PROBLEM STATEMENT ••..••...••...•...••..••.••...••..••...•..•...•...•..•...•...•..••. 1

1.3 0BJECTNE AND SCOPE OF THE PROJECT ...•..•...••..••...••...•..•...••.••...•..••..•.. 1

1.4 SIGNIFICANCE OF PROJECT ...•...•...•...••...•..••...•..••...••..•...•...• 2

1.5 RELEVANCY AND FEASIBILITY OF THE PROJECT ••...•...•...•...•..•... 2

CHAPTER 2 ... 3

LITERATURE REVJE.W ... 3

2.1 FIRE DETECTION SYSTEM ...•...•..••...•...•..•...••...•.••...•...•..••.•••...••.••..•..•....•...• 3

2.2 FLAME DETECTORS ..•...•..•.•..•...•..•...•..•...•...•..••...••...••..•...•.•...••...••... 4

2.2.1 Detector Cone of

Vision ...

4

2. 2. 2 Detection

range ...

5

2.3 HAzARD IN PROCESS PLANTS ••.••...••..•...•..•..•...•..•...•..••...••.••...•..••..•...••.. 6

2.4. FIRE DETECTION MAPPING ...•...•.••...•..•...•••...•..•...••..•...•....•.•...• 6

2.4 .1 HAZARD GRADING (MAPPING) ...•... 7

2. 4. 2 COVERAGE ASSESSMENT AND PERFORMANCE TARGETS ...•...•..••..•... 9

2.5 LOGICS 0VERVIEW •...•...•..•...•..•••..•....•••.••...••...•••..•...•.••.•••...•.•.•....•...••.•• 10

2. 5.1

Boolean

Logic ... 10

2.61NTRODUCTION TO IMAGE PROCESSING ••••...••..••...•....••..•...••.•...•...••...•.•...•..•..• 10

2. 6.1

Greyscale

image ... 10

2.6.2 Binary

image ... 11

2.6.3 RGB

image ...

12

CHAPTER 3 ... 13

MEmODOLOGY ... 13

3.1 PROJECTFLOWCHART .•...•..•...•..••...••.•...•..••.••...•...••.•...•..•...•...••.••...•••..•... 13

3.2

HAzARD

MAPPING OF THE PLANT MODEL.. •••.•...•..••...•...••.•.•...••...••..•...••.•••... 14

3.3 CONSTRAINTS OF THE PROJECT •...••.••..•...•...••..•...•.••..••...••.••.••...•..••..•...••.••... 15

3.4 MATLAB PROGRAMMING ••...•..•••...••...•...•...•..•...••.••...••..•... 16

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3.4.1 Hazard Map Image Processing ... 16

3.4.2 Detectors field of view (Mask) ... 17

3.4.3 Overlapping between detectors field of

view ...

18

3.4.4 Coverage Factor ... l9

3.5 TOOLS USED ..••.•...••..•...•...•..••...••.•••.••...•...••.••..•.••..•...•.•....•... 20

CHAPTER 4 ... 21

RESULTS AND DISCUSSION ... 21

4.1 TOPHAzARDMAP ..••...•....•.••..••.•...••...••..•..•...•...•..••.••...•.•...••...•... 21

4.1.1 One detector coverage factors ... 21

4.1.2 Two detectors coverage factors ... 23

4.1.3 Coverage factors of overlapping area ... 25

4.2 SIDE

HAzARD

MAP ••...•...•...•..••.••...•...•...•..•...•..•..••..•.••..•...•...• 27

4.2.1 One detector coverage factors ... 27

4.2.2 Two detectors coverage factors ... 28

4.2.3 Coverage factors of overlapping area ... 30

CHAPTER 5 ... 32

GRAPIDCAL USER INTERFACE OF THE PROJECT SOFTW ARE ... 32

5.1 DESCRIPTION OF THE GUI OF THE PROJECT SOFTWARE ...•...••.••...•...•..••...•.•• 32

5 .I USER GUIDE FOR OPTIMAL FIRE DETECTORS PLACEMENT SOFTWARE ..••.•..•..••...• 35

CHAPTER 6 ... 36

CONCLUSION AND RECOMMENDATION ... 36

6.1 CONCLUSION .•...•••...•••••.••...•...••.••...•..•..••.•••..•..••...•....••...•.• 36

6.2RECOMMENDATION ...•...••..•..••...•...•..•...•..•..•...•.•... 37

REFERENCES ... 38

APPENDICES ... 39

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LIST OF FIGURES

FIG.l DETECTOR CONE OF VISION ... 4

FIG.2 DETECTION RANGE ... 5

FIG.3 OVERLAPPING OF DETECTORS COVERAGE ... 5

FIG.4. STEP OF HAZARD GRADING IN HYDROCARBON PROCESSING AREA ... 8

FIG.5 HAZARD MAP (PREPARED BY MICROPACK) ... 8

FIG.6 GREYSCALE IMAGE ... 10

FIG. 7 UINT8 CLASS, PIXEL VALUE FALLS BETWEEN 0 (BLACK) AND 255 (WIDTE) ... 11

FIG.8 BINARY IMAGE ... I 1 FIG.9 RGB IMAGE ... 12

FIG.10 PROJECT FLOW CHART ... 13

FIG.11 HAZARDMAPMODEL ... 14

FIG.l2 TOP DETECTOR POSITION AND COVERAGE SHAPE ... 15

FIG. 13 SIDE DETECTOR POSITION AND COVERAGE SHAPE ... 15

FIG.l4 CONVERSION FROM RGB (A) TO GREYSCALE (8) ... 16

FIG.15 CONE SHAPE ... 17

FIG.l6 ONE DETECTOR COVERAGE ... 18

FIG.l7 TWO DETECTORS COVERAGE ... 18

FIG.l8 (A) OVERLAPPING COVERAGE (B) TOTAL DETECTOR COVERAGE ... 19

FIG.l9 (A) HAZARD MAP (B) AREA UNDER DETECTOR COVERAGE ... 19

F1G.20 (A) TOP HAZARD MAP (B) SIDE HAZARD MAP ... 21

FIG.21 IMAGE OF ONE DETECTOR COVERAGE FOR TOP VIEW ... 22

FIG.22 CHART OF ONE DETECTOR COVERAGE RESULTS FOR THE TOP VIEW ... 22

FIG.23 SOME IMAGE OF TWO DETECTORS COVERAGE FOR THE TOP VIEW ... 23

FIG.24 CHART OF TWO DETECTOR COVERAGE RESULTS FOR THE TOP VIEW ... 23

FIG.25 SOME IMAGES OF OVERLAPPING RESULTS FOR THE TOP VIEW ... 25

FIG.26 CHART OF TWO DETECTOR COVERAGE RESULTS FOR THE TOP VIEW ... 25

FIG.27 IMAGE OF ONE DETECTOR COVERAGE FOR THE SIDE VIEW ... 27

FIG28 CHART OF ONE DETECTOR COVERAGE RESULTS FOR THE SIDE VIEW ... 28

FIG.29 SOME IMAGES OF TWO DETECTORS COVERAGE FOR THE SIDE VIEW ... 28

FIG.30 CHART OF TWO DETECTORS COVERAGE RESULTS FOR THE SIDE VIEW ... 29

FIG.31 SAMPLES OF THE OVERLAPPING COVERAGE FOR THE SIDE VIEW ... 30

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FIG.32CHART OF TWO DETECTORS' OVERLAPPING COVERAGE RESULTS FOR TilE SIDE

VIEW ... , .. , ... , ... 31

FIG.33 GRAPIDCAL USER INTERFACE WINDOW,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 32 Fl G .34 PUSHB UTTO NS,, ,, , , , , , , , , ,,, , , , , , , , ,,,,,,,,,,, ,, ,, , , , , , , ,, , , , , , , , , , , , , , , ,,,,,,,. 3 3 FIG .35 WINDOW TO DISPLAY THE LOADED HAZARD MAP,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,. 33 FIG.36 TABLES OF TilE COMPUTED RESULTS,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, 34 FIG.37 LIST BOXES TO ASSIST TilE USER TO LOCATE TilE EXACT DETECTOR POSITION

AT TilE LAY OUT. , , , , ,,, , , , , , , ,, ,, , , , , , , ,,,,,,,,,,,,,,, ,, , , , , , , ,, , , , , , ,, ,, ,, ,, , , , , , , ,,,. 34

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