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ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
ASAB – 2 ASAB GAS DEVELOPMENT PHASE II PROJECT 5228
OPERATING MANUAL CHAPTER 18 FIRE FIGHTING - UNIT 273
DOCUMENT CLASS: 2
EASTERN BECHTEL COMPANY LIMITED
THE DESIGN OR PART THEREOF CONTAINED IN THIS DOCUMENT WAS DEVELOPED FOR GASCO FOR THE PROJECT AND REMAINS THE PROPERTY OF GASCO. ALL EASTERN BECHTEL COMPANY LTD (EBCL) PROPRIETARY INFORMATION OR UNDERLYING INTELLECTUAL PROPERTY UTILIZED IN THE CREATION OF THE DESIGN OR INFORMATION CONTAINED HEREIN SHALL REMAIN THE PROPERTY OF EBCL.
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18-1
GASCO PROJECT NO. 5228
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
This page records the revision status of this document. All previous issues are hereby superseded and are to be destroyed. NOTES: Revisions after Rev. 1 are denoted as follows: (a) By a vertical line in the right-hand margin adjacent to the revised text. The revision number is displayed adjacent to the right hand side of the revision line, or (b) By a triangle symbol for graphics, the revision number being denoted within the symbol positioned adjacent to the revision. (c) CHKD = Checked by Project Functional Manager, or nominee; DISC = (Corporate) Functional Manager, or designee; PD = EBCL's Project Director, or designee
REV
DATE
REASON FOR ISSUE
BY
CHKD
1 0
18 Nov 08 11 Oct 08
Issued for Implementation Issued for Review
M&H M&H
CBM CBM
DISC
AMCI AMCI
APPROVED PD PMC
GASCO
IR IR
Signed (Initials)
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18-2
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
TABLE OF CONTENTS 18.1
OVERVIEW ....................................................................................................................................... 6
18.2
PROCESS DESCRIPTION .............................................................................................................. 7
18.3
18.2.1
Firewater Pumps and Headers .......................................................................................... 7
18.2.2
Deluge Systems .................................................................................................................... 8
18.2.3
Inergen® Fire Suppression Systems ................................................................................. 8
18.2.4
Very Early Smoke Detection Apparatus (VESDA™) ..................................................... 9
18.2.5
Carbon Dioxide System ...................................................................................................... 9
EQUIPMENT DESCRIPTION ...................................................................................................... 10 18.3.1
Diesel Fire Pump ............................................................................................................... 10
18.3.2
Fire Hydrant Monitors, Hose Reel Foam Stations and Fire Hydrants ....................... 10
18.3.3
Deluge Systems .................................................................................................................. 11
18.3.4
Inergen® Fire Suppression Systems ............................................................................... 12
18.3.5
VESDA ............................................................................................................................... 13
18.3.6
Carbon Dioxide System .................................................................................................... 14
18.3.7
Fire Alarm Systems .......................................................................................................... 14
18.4
OVERPRESSURE PROTECTION DEVICES ............................................................................ 16
18.5
UNIT CONDITIONING ................................................................................................................. 16
18.6
OPERATING VARIABLES AND CONTROLS .......................................................................... 19
18.7
18.6.1
Diesel Fire Pump ............................................................................................................... 19
18.6.2
Fire Monitors, Hydrants, and Headers........................................................................... 21
18.6.3
Deluge Systems .................................................................................................................. 21
18.6.4
Inergen® Fire Suppression System ................................................................................. 21
18.6.5
Carbon Dioxide System .................................................................................................... 21
18.6.6
VESDA ............................................................................................................................... 21
SAFETY PRECAUATIONS........................................................................................................... 22 18.7.1
General............................................................................................................................... 22
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18-3
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.8
18.9
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
18.7.2
Diesel Fire Pump ............................................................................................................... 23
18.7.3
Fire Monitors and Hydrants ............................................................................................ 23
18.7.4
Inergen® Fire Suppression System ................................................................................. 23
18.7.5
Carbon Dioxide System .................................................................................................... 24
18.7.6
VESDA ............................................................................................................................... 24
PRE-STARTUP CHECKS ............................................................................................................. 24 18.8.1
Diesel Fire Pump ............................................................................................................... 24
18.8.2
Fire Monitors, Hydrants, and Headers........................................................................... 25
18.8.3
Deluge Systems .................................................................................................................. 26
18.8.4
Inergen® Fire Suppression System ................................................................................. 26
18.8.5
Carbon Dioxide System .................................................................................................... 26
18.8.6
VESDA ............................................................................................................................... 27
INITIAL STARTUP ........................................................................................................................ 27 18.9.1
Diesel Fire Pump ............................................................................................................... 27
18.9.2
Fire Monitors, Hydrants, and Headers........................................................................... 28
18.9.3
Deluge Systems .................................................................................................................. 28
18.9.4
Inergen® Fire Suppression System ................................................................................. 28
18.9.5
Carbon Dioxide System .................................................................................................... 29
18.9.6
VESDA ............................................................................................................................... 29
18.10 NORMAL STARTUP ..................................................................................................................... 29 18.10.1 Diesel Fire Pump ............................................................................................................... 29 18.10.2 Inergen® Fire Suppression System ................................................................................. 30 18.10.3 Carbon Dioxide System .................................................................................................... 30 18.10.4 VESDA ............................................................................................................................... 30 18.11 NORMAL OPERATION ................................................................................................................ 30 18.11.1 Diesel Fire Pump ............................................................................................................... 30 18.11.2 Fire Monitors, Hydrants and Headers............................................................................ 31 18.11.3 Inergen® Fire Suppression System ................................................................................. 31 18.11.4 Carbon Dioxide System .................................................................................................... 31
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18-4
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
18.11.5 VESDA ............................................................................................................................... 32 18.12 NORMAL SHUTDOWN ................................................................................................................ 32 18.12.1 Diesel Fire Pump ............................................................................................................... 32 18.12.2 Fire Monitors, Hydrants, and Headers........................................................................... 32 18.12.3 Inergen® Fire Suppression System ................................................................................. 33 18.12.4 Carbon Dioxide System .................................................................................................... 33 18.13 EMERGENCY OPERATING CONDITIONS ............................................................................. 33 18.13.1 Diesel Fire Pump ............................................................................................................... 33 18.13.2 Inergen® Fire Suppression System ................................................................................. 34 18.13.3 Carbon Dioxide System .................................................................................................... 34 18.14 REFERENCES ................................................................................................................................ 34 18.15 ATTACHMENTS ............................................................................................................................ 35
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18-5
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.1
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
OVERVIEW Fire fighting equipment is positioned in strategic locations throughout the ASAB-2 area. Most fire fighting systems in place are fire suppressant based, eliminating fires that may occur and preventing fires spreading to adjacent equipment. Basic fire protection and suppression equipment includes firewater pumps that supply a firewater distribution header, which feeds deluge systems and spray heads, fire monitors, and fire hydrants. This type of system protects tanks and equipment that will not be harmed or damaged when exposed to water. Carbon Dioxide and Inergen® Fire Suppression Systems deliver clean fire suppression agents to extinguish fires. These types of fire suppression systems are normally used in spaces where electronics or electrical equipment are located, where water type extinguishers will damage equipment or where water will cause an electrical shock hazard. The fire water deluge system design is based on not more than two fires being fought simultaneously. ASAB-2 uses the following systems to protect personnel and equipment in a fire emergency:
Firewater storage tanks Diesel and electric firewater pumps Jockey pumps Fire monitors Hose connections Deluge systems Inergen® Fire Suppression Systems Carbon dioxide (CO2) fire extinguishing system assemblies Hose Reel Foam (HRF) Miscellaneous other fire fighting equipment Periodic training Equipment checks are performed to maintain system function as designed and ensure that they are continually ready for service.
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18-6
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
18.2
PROCESS DESCRIPTION
18.2.1
Firewater Pumps and Headers
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
Fire fighting System components include the following:
Firewater pumps
Firewater headers
HRF stations
Firewater monitors
Fire hydrants
Sprinkler/deluge systems.
A new Diesel Fire Pump 273-P-101 is installed at ASAB-1 to be operated with the Main ASAB-1 Electric Fire Pump 173-P-101A and Diesel Fire Pump 173-P-101S. Under normal conditions, the new Diesel Firewater Pump is in standby. Firewater pumps on Units 173 and 273 draw suction from ASAB-1 Firewater Storage Tanks 161-TK-101A/B and 161-TK-102A/B through an 18-inch line. The Unit 273 Diesel Fire Pump in Fire Pump Building 273-BLD-001 is equipped with a Diesel Day Tank 273-TK-101 providing sufficient diesel for 12-hours operation. The level in the diesel day tank is routinely checked and is refilled after extended operation of the Diesel Fire Pump. The ASAB-1 electric driven firewater Jockey Pumps 173-P-102A/S maintain the minimum firewater system header pressure between 7.0 and 8.0 barg at all times. The pumps only operate when the pressure on the firewater header decreases sufficient to activate a pressure switch that starts the pump selected for Duty operation. The main section of the firewater header is buried, so post indicator valves (PIV) are used to isolate portions of the firewater header during line rupture or maintenance. Firewater monitors are used to manually direct firewater to a target area. These manually operated monitors are equipped with adjustable spray nozzles that the operator can use to vary the width of the water stream from a straight stream to a fog/mist pattern. Fire hydrants are installed throughout the facility for use with fire hoses, if needed during an emergency. Branch lines from the main firewater header supply water to deluge systems throughout the unit. During a deluge operation, as the firewater header pressure decreases, the firewater pump selected for Duty service automatically starts to increase pressure and water to the activated deluge system.
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18-7
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.2.2
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
Deluge Systems The Deluge Systems are divided into zones, each protecting a particular area of the process or piece of equipment. Each zone has a deluge control station that operates automatically during a fire or can be activated manually by the operator at the deluge valve and out in the field via a manual pull station. Each water spray system is equipped with linear heat sensor type (24 V) insulated wire conductors, intrinsically safe for automatic activation of the deluge system. Activation in a single loop results in a fault alarm, while activation in both loops results in a fire alarm (two of two voting system). Firewater system pressure is maintained up to the deluge valve at all times. The deluge valve remains closed until an open signal is received from a heat sensing device. When the deluge valve opens, the firewater header pressure decreases and automatically starts the Firewater Pump selected for Duty service to increase pressure and water to the activated deluge system. Once the system is reset, the applicable Firewater Pumps need to be manually turned off. A Simplex 4100U Local Fire Alarm Panel (LFAP) is installed on each deluge skid at the Deluge Valve Stations (DVS). The Master Fire Alarm Panel (MFAP) in the control building receives all fire alarms and activation signals from the LFAPs via the site-wide Fire Alarm System (FAS) network.
18.2.3
Inergen® Fire Suppression Systems Instrument Equipment Shelters (IES), Electrical Substations (ES) and Variable Speed Drive (VSD) buildings are protected by Inergen® Fire Suppression Systems. Inergen® protected areas have detection loops with smoke and heat detectors that initiate on 2 of 2 voting. Inergen® is a trademarked fire suppression product of Ansul Corporation. Inergen is a blend of inert atmospheric gases that contains 52% nitrogen, 40% argon, 8% carbon dioxide. It is nontoxic. Inergen is used at concentrations of 40-50% to lower the concentration of oxygen to a point that cannot support combustion. The system comprises high pressure gas cylinders containing Inergen®, connected to a network of pipe fitted with open spray nozzles. When the system trips, gas is released into the protected space that alarmed. Although the clean gas is safe for humans, equipment and the environment, the area should be evacuated after the gas is released. There are two racks of Inergen® bottles. The main cylinder bank is in service at all times unless maintenance is being performed on the system or there is a need to change out empty bottles. A reserve cylinder bank provides a backup to the main cylinder bank. Valves have to be manually repositioned to place one bank in service while the other is isolated.
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18-8
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
Each local fire alarm panel (LFAP) is provided with monitor modules/input modules for monitoring and controlling the following:
Fire Detectors (per Inergen® protected room)
Manual abort switch (per Inergen® protected room) Auto/Manual change over switch (per Inergen® protected room) Pressure switch (per Inergen® protected room) Manual release switch (per Inergen® protected room)
The LFAP is provided with control modules and output modules for activating the following:
Cylinder actuation solenoid valve (1 on each main and reserve cylinder bank/per area) Directional solenoid valve (1 for each Inergen® protected room) Suppressant status lights (1 for each Inergen® protected room) Suppressant pre-discharge audible/visual alarm
Input signals received from the Inergen® systems are communicated over the Fire Alarm System (FAS) network and transferred as common zone signals to the DCS and Alarm Management System (AMS) at the control building. 18.2.4
Very Early Smoke Detection Apparatus (VESDA™) Very Early Smoke Detection Apparatus (VESDA™) is a brand of aspirating smoke detector which is capable of detecting the microscopic particles of smoke. VESDA™ detection systems are installed for the IES, ES, VSD and ASAB-1 computer room for the purpose of void and cabinet smoke detection. Each of the VESDA detection systems will comprise a detector unit, power supply, sampling pipe works and integral programmer to provide early warning of any detected smoke within the monitored areas.
18.2.5
Carbon Dioxide System The CO2 system consists of a single CO2 cylinder mounted outside HVAC control cabinets and discharges through a single nozzle inside the cabinet. All HVAC cabinets protected by a CO2 system have smoke and heat detectors installed inside the cabinets on a detection loop of the LFAP. On detection, activation is initiated from the LFAP. Monitoring and control of the CO2 system is by the following:
Smoke and heat detectors on the detection loop located inside the HVAC cabinets A monitor module/input module for monitoring the CO2 discharge pressure switch An extinguisher control module for activating the discharge system
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18-9
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
An output control module for activating the CO2 discharge alarm An output control module for activating the CO2 status light
Input signals received from the CO2 systems are communicated over the site-wide Fire Alarm System (FAS) network and transferred as common zone signals to the DCS and Alarm Management System (AMS) at the control building. 18.3
EQUIPMENT DESCRIPTION The major components of the ASAB-2 fire fighting system include the following:
18.3.1
Diesel Fire Pump 273-P-101 Fire Hydrants Fire Monitors Hose Reel Foam Stations Deluge Systems Inergen® Fire Suppression Systems VESDA™ Systems CO2 HVAC Cabinet Fire Suppression Systems Fire Alarm Systems
Diesel Fire Pump The new centrifugal type Diesel Fire Pump 273-P-101 located in ASAB-1 has 18-inch suction and 12-inch discharge nozzles. The pump has a rated flow of 794m3/hr and a differential head of 119m. The design pressure is 12.6 barg at a maximum temperature of 40°C. A local Fire Pump control panel provides start/stop and monitors pump operation. The pump is housed in the Fire Pump Building 273-BLD-001 to protect the equipment from exposure to the elements. The Diesel Fire Pump system includes an elevated Fire Pump Diesel Day Tank 273-TK-101 to store fuel for diesel unit operation. The tank is non-insulated and is constructed of carbon steel with dimensions of 1,225mm (OD) by 2,184.4mm (long) and a capacity of 2.5m3, which provides approximately 12 hours run time. Diesel is gravity fed from the tank to the suction of the diesel engine fuel pump.
18.3.2
Fire Hydrant Monitors, Hose Reel Foam Stations and Fire Hydrants Fire Hydrant Monitors are strategically located in process areas. Monitors have a 500 gpm capacity with fog and straight stream capability. Hydrant outlets are 2½ inch for fire hose connection.
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18-10
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Fire hydrants are located with in non-process areas, with 6-inch risers fed from a 6-inch header. Fire hydrants also have 2½ inch outlets for fire hoses to be connected. Hose Reel Foam stations are strategically located inside ASAB-2. Hose reel stations are equipped with 31 meters of 1½ inch, 19 mm internal bore, 500psi non-collapsible rubber hose and adjustable flow, combination straight-stream fog type (all brass) nozzles. Manifolds, including an eductor, are provided at each station to permit the use of water only or to allow the introduction of foam from a foam tank. Hose reel stations are protected inside weatherproof, closed cabinets. 18.3.3
Deluge Systems The deluge systems are instrument air operated, automatic sprinkler/ deluge systems designed to flood an area with enormous amounts of firewater during a fire. All the systems can be tripped manually and will continue to flow firewater after a trip until the water supply valves are manually closed and the system is reset by the outside operator. Table 18.3.3-1 identifies the location of each deluge system. Table 18.3.3-1: Location of Deluge Systems Deluge System
Deluge Valve
DVS-01
WDS-241-1
241-C-107 A/S
WDS-241-3
241-V-111, P-101 A/B/S, P-104 A/S, V-110
WDS-241-6
241-C-201
WDS-241-4
241-C-102,CT-102, E-105, V-121
WDS-241-5
241-CM-002,280-EE-0519
WDS-241-2
241-V-201, V-202, V-205, V-206
DVS-02
Protected Equipment
DVS-03
N/A
DVS-04
WDS-141-1
141-C-107 A/S
WDS-141-3
141-V-111, P-101 A/B/S, P-104 A/S, V-110
WDS-141-6
141-C-201
WDS-141-4
141-C-102,CT-102, E-105, V-121
WDS-141-5
141-CM-002,280-EE-0618
WDS-141-2
141-V-201,V-202,V-205,V-206
WDS-145-1
145-C-101 A/S
WDS-145-2
145-P-101 A/S, P-102 A/S, P-103 A/S
WDS-226-4
226-V-101-B
WDS-226-5
226-V-101-B
WDS-264-1
264-V-102
WDS-226-2
226-V-101-A
DVS-05
DVS-06 DVS-07
DVS-08
N/A
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18-11
GASCO PROJECT NO. 5228
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Deluge System
Deluge Valve
226-V-101-A
WDS-226-1
226-P-101 A/B/S
WDS-999-1
280-EE-0710 A
WDS-999-2
280-EE-0710 B
WDS-999-3
280-EE-0715
WDS-153-1
153-C-101 A
WDS-153-2
153-C-101 B
WDS-153-3
153-C-101 S
WDS-191-1
191-C-101/ CT-101
WDS-291-1
291-C-101/CT-101
WDS-266-1
266-ME-101
DVS-11
WDS-264-2
264-V-101, P-101 A/S, P-105
DVS-12
WDS-999-4
280-EE-0610 A
WDS-999-5
280-EE-0610 B
WDS-220-1
280-EE-510 A
WDS-220-2
280-EE-510 B
WDS-999-6
280-EE-0511 A
WDS-999-7
280-EE-0511 B
WDS-999-8
280-EE-0512 A
WDS-999-9
280-EE-0512 B
DVS-10
DVS-13
DVS-14
Rev. 1
Protected Equipment
WDS-226-3 DVS-09
18.3.4
Agreement No 13522801
Inergen® Fire Suppression Systems Inergen® duty cylinder banks are backed up with equivalent reserve cylinder banks. Cylinder charging pressure is 200 barg at 21°C. Each cylinder is equipped with a pressure seat-type valve equipped with a pressure gauge. The valve includes a safety pressure relief device designed to operate between 276 and 309 bar. Cylinders are located in containers equipped with lights and a HVAC window unit to protect them from the elements. A local Fire Alarm Panel is provided in each of the buildings protected by Inergen® to identify the status of the Inergen® Fire Suppression System. Table 18.3.4-1 identifies the location of each protected area. Table 18.3.4-1: Location of Inergen® Fire Suppression Systems Extinguishing Assembly Number
Protected Building
Protected Rooms
273-ME-102
IES-005
Instrument Room
273-ME-103
IES-005
UPS Room
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18-12
GASCO PROJECT NO. 5228
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Extinguishing Assembly Number
18.3.5
Agreement No 13522801
Protected Building
Rev. 1
Protected Rooms
273-ME-102
220 kV Substation
Switchgear Room, Battery Room, ADWEA Room
273-ME-103
Substation ES-005
Switchgear Room
273-ME-104
Substation ES-005
UPS/Battery Room
273-ME-105
IES-005
Instrument Room, UPS/Battery Room
273-ME-112
Substation ES-006
Switchgear Room
273-ME-113
Substation ES-006
UPS/Battery Room
273-ME-114
IES-006
Instrument Room, UPS/Battery Room
273-ME-116
Substation ES-006
UPS/Battery Room
273-ME-117
241-SEL-001
VSD Room
273-ME-118
141-SEL-001
VSD Room
273-ME-121
Substation ES-007/IES-007
Switchgear Room
273-ME-122
Substation ES-007/IES-007
UPS/Battery Room
273-ME-123
Substation ES-007/IES-007
Instrument Room, UPS/Battery Room
273-ME-124
Substation ES-008
Switchgear Room
273-ME-125
AGD I Control Room
Computer Room
VESDA Air is drawn into a VESDA detector by the aspirator from up to four sampling pipes through two filter assemblies. These filters screen out larger airborne particles from the smoke sample before it enters a laser chamber. A laser beam passes through the air sample and is scattered by any smoke particles. The scattered light is measured by high-sensitivity photo sensors and converted into a signal that represents the percent of obscuration. Air is continuously drawn in from all sectors in use by a proprietary, high efficiency aspirator. A sample of this air is passed through the laser chamber to measure the smoke density. When the smoke intensity reaches the Adaptive Scan threshold level, the detector performs a Fast Scan operation by opening and closing the valves to identify the sample pipe that is carrying the smoke. If there is more than one pipe transporting the smoke, the sector with the highest smoke concentration is designated as the First Alarm Sector. Once the source has been located, other sectors are then monitored to determine the spread of fire within the area being monitored. As the laser scanner detects threshold levels of smoke four different alarms may be activated, depending on threshold levels reached. These are Alert, Action, Fire 1 and Fire 2.
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18-13
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.3.6
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Carbon Dioxide System Fifteen Carbon Dioxide Fire Extinguishing Systems protect the HVAC control panels. Table 18.3.6-1 identifies the location of each system. Table 18.3.6-1: Location of Carbon Dioxide System for HVAC Systems Extinguishing Assembly Number
18.3.7
Protected HVAC System
273-ME-107A
IES-005
273-ME-107S
IES-005
273-ME-108A
IES-006
273-ME-108S
IES-006
273-ME-109A
Substation ES-005
273-ME-109S
Substation ES-005
273-ME-110A
Substation ES-006
273-ME-110S
Substation ES-006
273-ME-111A
Substation ES-007
273-ME-111B
Substation ES-007
273-ME-111C
Substation ES-007
273-ME-111D
Substation ES-007
273-ME-126
220 kV Switchgear
273-ME-130
141-SEL-001
273-ME-131
141-SEL-002
273-ME-132
241-SEL-001
273-ME-133
Substation ES-008
Fire Alarm Systems The Fire and Gas System (FGS) for ASAB-2 includes equipment in the following locations:
Fire and Gas Panel for IES 5, IES 6 and IES 7 Fire and Gas Equipment in the new computer room (NCR) at the Gas Plant Control Room Operator notification equipment in the Gas Plant Control Room (GCPR) Alarm Printer in Fire Station
Fire and gas field devices such as gas detectors, manual stations, strobe lights and horns, connect to fire control panels located in each IES. The fire and gas control panel in IES 7 is also connected to the Booster Compressor fire and gas panel by a redundant serial communications link. The fire and gas components in each location are connected by a dedicated redundant fire and gas peer to peer network using Vnet/IP protocol.
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18-14
GASCO PROJECT NO. 5228
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Each IES is provided with a desktop workstation and a laptop computer. The NCR is provided with a desktop engineering workstation and a laser printer. The Yokogawa Human Interface Station (HIS) workstation in the GPCR and in each IES displays status screens for the fire and gas system. Alarm printers located in the GPCR and in each IES prints all fire and gas alarms, system faults, and other events in the order in which they occur, including a time stamp, tag number, description, process data and type of alarm. Two additional HIS workstations dedicated for fire and gas are located in the Fire Station. IES FGS Systems The fire and gas control panel in IES consists of a server cabinet, system cabinets and marshalling cabinets. The server cabinets house communication switches and OPC servers. The system cabinets house the ProSafe-RS controller and I/O modules. The marshalling cabinets house the field cable terminations, ProSafe-RS field termination units, output relays and redundant field power supplies. The system cabinets are connected to the marshalling cabinets in each IES. A desktop workstation in each IES provides for display and maintenance. The workstation connects to redundant Vnet/IP switches that are connected to the redundant fire and gas peer to peer network. A laptop computer is supplied with a converter box which allows it to connect to the Vnet/IP switches. Two sets of redundant OPC servers are provided in IES 5 providing redundant OPC connections to the AMS and DCS. The OPC servers connects to the redundant fire and gas peer to peer network via the redundant Vnet/IP switches. Table 18.3.7-1 lists the components pf the FGS system in each IES. Table 18.3.7-1 IES FGS System Components in each IES Server Cabinets
System Cabinets
Marshalling Cabinets
Desktop Workstation
Laptop Computer
IES 5
1
1
1
1
1
IES 6
1
2
2
1
1
IES 7
1
2
2
1
1
NCR FGS System A server cabinet houses the communication switches and OPC servers. A desktop engineering workstation is provided for display and maintenance. The workstation connects to redundant Vnet/IP switches that are connected to the redundant fire and gas peer to peer network. A laser printer will also be provided in the NCR to provide printing functionality for the fire and gas desktop engineering workstation.
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18-15
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
Three sets of redundant OPC servers provide redundant OPC connections to the AMS, DCS and FAS. The OPC servers connect to the redundant fire and gas peer to peer network via the redundant Vnet/IP switches. Notification of operators in GPCR of fire alarms is by I/O circuits wired to and from the I/O modules of the fire and gas systems. GPCR Operator Notification Equipment The Master Fire Alarm Panel (MFAP) is a Yokogawa Human Interface Station (HIS), text based alarm messaging system used to notify GPCR personnel of fire and gas alarms and faults. Audible notification is achieved with integrated audio card and speaker inside the HIS and driven by the alarm messaging system. The alarm messaging system prints to a line printer supplied with the HIS. The dedicated fire and gas system line printer prints fire and gas system alarms and faults. The HIS also prints fire and gas alarms and faults to a second line printer located in the Fire Station. Fire Station Alarm Printer A line printer is provided in the Fire Station for printing fire and gas alarms and faults. The printer repeats alarms and faults printed on the GPCR printer. The printer is connected to the NCR server cabinet and to the fire and gas peer to peer network by fiber optic cable. 18.4
OVERPRESSURE PROTECTION DEVICES Diesel Fire Pump, 273-P-101 has one pressure safety valve (PSV) PSV-150 located on the pump discharge, which is set at 12 barg. If the firewater pressure exceeds this set point, excess pressure is released into the fill header to Firewater Storage Tanks 161-TK-102A/B.
18.5
UNIT CONDITIONING All pre-commissioning and commissioning activities must be completed before the unit is ready for operation. These include, but are not limited to, verifying the following requirements:
All safety systems and equipment are in place and fully operable. Actuated valves are installed and tagged correctly, lubricated, and stroked to confirm proper operation. Bypasses are appropriately aligned and locked closed as necessary Pressure relief valves and devices are correctly calibrated for their location and are installed correctly. All sensing elements which were removed from pipe work prior to leak testing have been reinstated. Temporary filters, construction and commissioning blinds are removed. Test equipment and special tools, if any, and facilities for their operation are available.
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18-16
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
All functional test procedures are complete. All instruments have been calibrated, loop checked, and commissioned. Control and shutdown loops are functional and tested The Fire Alarm is operational and tested. Electrical power systems have been checked out and commissioned and Power is available to all electric drivers, control systems, and panels. All utilities have been commissioned, lined up and are ready for use at the unit battery limit, unless otherwise stated in this document. Motor directions are checked if they have been worked on. All rotating equipment and associated drivers are aligned, run in and lubricated, as required, in accordance with manufacturers' recommended procedures. All Vendor equipment is commissioned and operators are fully acquainted with its use. All A and B punch list items have been completed.
The following system specific verifications and checks are performed when equipment is initially placed in service, either during commissioning or after a major outage:
Diesel Fire Pump Specific Operations Confirm tubing and piping connections are secure. Verify diesel fuel tank is clean before filling. Verify oil and fuel filters are in place. Verify oil level in diesel engine is at full mark. Top up with appropriate grade of oil if level is low. Verify radiator water level is full. Verify starting battery is fully charged. Ensure engine warmers are in service, if applicable. Firewater pump check valve line up is as expected. Confirm firewater pump PSV is installed, set at the correct pressure and valves aligned if provided. Check housekeeping is performed in Diesel Fire Pump building. Flush firewater header to grade. Bleed air from firewater system and through pump. Notify supervisor of any problems encountered.
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18-17
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
Fire Monitors, Hydrants, and Headers Verify ease of movement of fire monitor, left/right and up/down. Verify spray nozzle is easily adjusted. Lubricate fire monitors, as applicable. Test flow firewater through fire monitor to check operation of spray nozzle. Confirm no leaks after testing. When inspection is completed, leave spray nozzle in the mid-range setting. Set fire monitor into down position when not in service to allow for drainage. Check thread connections on hydrants and install protective caps. Ensure hydrant valves are fully closed. Visually check that soil around hydrant is firm, erosion not present. Verify post indicator valves (PIV) show the proper setting (open or closed). Notify supervisor of any problems encountered.
Deluge Systems Check piping and connections for system are secure. Check with Fire Protection Contractor and verify that lines have been flushed clean. Ensure proper valve alignment to applicable Deluge System. Verify there is sufficient instrument air pressure available at Deluge System. Verify firewater pressure is present Check that deluge spray nozzles are free of obstructions. Flow test system to ensure acceptable spray patterns. Notify supervisor of any problems noted.
Inergen® Fire Suppression System Verify cylinders are filled to the required pressure on local pressure gauges. Ensure local fire alarm panel is powered up. Align valves as required for system operation. Verify dispensing nozzles are not blocked or plugged. Check that the system functions properly on dry test. The dry test consists of testing the smoke detection system and 2 out of 2 voting for proper activation of each of the protected areas. Check with Fire Protection Contractor and verify that lines have been checked to be clean. Notify supervisor of any problems detected.
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18-18
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Carbon Dioxide System Check cylinders are filled to required pressure on local pressure gauge. Ensure local fire alarm panel is powered up. Align valves as required for system operation. Verify dispensing nozzles are not blocked or plugged. Check smoke and heat detectors are operational and the area around smoke and heat detectors is free of obstructions. Verify system functions properly during dry test. The dry test consist of testing the heat and smoke detection system 2 of 2 voting for proper activation of each of the protected HVAC control panel. Notify supervisor of problems that are detected.
VESDA™ Check and verify VESDA™ program operation. Verify alarm signals back to the LFAP. Verify sampling air pipes are firmly connected to the air inlet ports. Test each sector pipe for proper alarm signals
Any active alarms associated with any of the above systems must be investigated and rectified before startup. 18.6
OPERATING VARIABLES AND CONTROLS
18.6.1
Diesel Fire Pump The Diesel Fire Pump 273-P-101 has several critical operating variables that could damage the diesel driver. The pump starts automatically when selected for Duty service. During operation, the parameters in Table 18.6.1-1 must be monitored and maintained to ensure proper operation. Table 18.6.1-1: Diesel Fire Pump Operating Points for Key Variables Variable
Normal Range
Oil pressure
4.5 barg
Oil temperature
88°C
Jacket water temperature
88°C
Revolutions per minute (rpm)
1,650
Firewater pressure
7.0 - 8.0 barg
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18-19
GASCO PROJECT NO. 5228
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
The Diesel Fire Pump has a high jacket water temperature alarm and a low oil pressure alarm and shuts down on high jacket water temperature, low oil pressure and overspeed. Table 18.6.1-2: Diesel Fire Pump Control Panel Alarms and Push Buttons Indicator Lamp or Switch
Function
Manual/Off/Auto
Selector switch to set mode of operation: Manual for local operation, Off to isolate for maintenance and Auto for automatic operation
Crank on Battery 1
Push button for starting with battery, Bank #1
Crank on Battery 2
Push button for starting with battery, Bank #2
Stop
Push button used to stop operation of diesel
Power On
Indicator light indicating power available to system
Main Switch in Auto
Indicator light indicating system is in Auto mode of operation
Alarm
Indicator light to indicate an alarm is in on system
Engine Failed to Start
Indicator light to indicate engine failed to start
Charger Malfunction
Indicator light to indicate battery charger has a malfunction
Battery #1 Trouble
Indicator light to indicate Battery Bank #1 has a problem
Battery #2 Trouble
Indicator light to indicate Battery Bank #2 has a problem
System Pressure Low
Indicator light to indicate Firewater system pressure low
Engine Running
Indicator light to indicate engine is in operation
Engine Coolant Temp. High
Alarm light to indicate high cooling water temperature
Engine Oil Pressure
Alarm light to indicate low oil pressure
Engine Overspeed
Alarm light to indicated engine shut down due to overspeed
Low Fuel Level
Alarm light to indicated low fuel level in diesel day tank
Table 18.6.1-3: Diesel Fire Pump Control Panel Alarms, Shutdowns, and Tag Numbers Variable
Tag No.
Function
High CW Temperature
273-TAH-830
Advisory warning alarm on high cooling water temperature
Battery/Charger Failure (Power Supply Malfunction)
273-XA-833
Advisory alarm on loss of electrical power to charger/battery
Pump On Demand
273-XA-831
Engine Running
273-XL-834
Indicator that engine is in operation
Low Oil Pressure
273-PAL-830
Alarm and shutdown indication
Low Fuel Level
273-LAL-830
Advisory alarm -on low fuel level in Fire Pump Diesel Day Tank
Engine Trouble
273-XA-832
Engine problems, vibration, general
Pump Auto Signal Start
273-XA-830
Allows diesel to start when in Auto mode of operation
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18-20
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.6.2
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
Fire Monitors, Hydrants, and Headers Fire monitors and hydrants have sufficient firewater pressure for the equipment to function as designed. The firewater header pressure is maintained between 7.0 - 8.0 barg. Low firewater pressure prevents proper application of spray patterns from fire monitors and hydrants when placed in operation.
18.6.3
Deluge Systems Deluge Systems require adequate firewater pressure for the spray nozzles to apply water to the area as designed. Instrument air pressure is also needed for automatic valves to operate. Deluge systems are designed at several different pressures. The existing firewater header is maintained at about 7.0 barg and the instrument air header pressure for the deluge system is set at approximately 7.5 barg.
18.6.4
Inergen® Fire Suppression System This system functions automatically, but can be tripped manually from the local Fire Control Panel. Normally, the Auto/Manual changeover switch is in the Auto position with No Alarm lights illuminated. Alarm problems should be resolved as quickly as possible. Depending on valve alignment, either the Main or Reserve Cylinder Bank discharges Inergen® gas to the area detecting a fire. The normal operating pressure for the system is 200 barg. Each cylinder is equipped with a pressure seat type valve equipped with a pressure gauge. The valve includes a safety relief device designed to operate at between 276 and 309 barg.
18.6.5
Carbon Dioxide System The Carbon Dioxide (CO2) System also functions automatically and the operator can manually trip the system if needed. A status light indicates whether the system is ready for service. The normal operating pressure for the system is 58.6 barg. The system status is monitored at the local Fire Alarm Panel.
18.6.6
VESDA The VESDA™ control panel monitors the air flow and filter and reports alarms and trouble signals to the Local fire alarm panel (LFAP). Each VESDA™ is interfaced to a LFAP and provides up to six signals as follows:
Fire - one per pipe sector up to four pipes per system Fault Isolate
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18-21
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
18.7
SAFETY PRECAUATIONS
18.7.1
General
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
This chapter contains safety information on the installed systems. If not handled properly, all hydrocarbons and chemicals can be dangerous, so operators should be aware of the hazardous properties of materials in use and trained in the correct procedures for handling these materials. The hazardous nature of the diesel fuel for pump 273-P-101 requires regular inspections of all equipment items, piping and valves. Leaks must be reported immediately and remedial actions initiated as soon as possible. Operators must also be aware of the hazard of hydrogen sulphide, (H2S), which can cause unconsciousness and death even in relatively low concentrations. H2S poses a serious area hazard. It readily forms explosive mixtures with air. When burning, it generates sulphur dioxide (SO2) and water while evolving heat. The H2S auto-ignition temperature is 260°C and the explosive range is 4.3% to 46% v/v. H2S is present below 20 ppmv in the residue gas but up to 200 ppmv in makeup sales gas. Hydrogen Sulphide (H2S) and Ammonia vapours may be present where stripped sour water is collected, so personnel undertaking fire system checking/maintenance in areas where there components may be present should be aware of the risks and potential consequences when dealing with these streams. Operators must wear proper personal protective equipment (PPE) appropriate to any task undertaken and be properly trained in the use and application of this PPE. Examples of PPE include safety glasses and gloves when working around equipment. Operators must familiarize themselves with the location and use of fire fighting and safety equipment and be thoroughly familiar with basic first aid measures and capable of taking appropriate action in the event of an incident. Periodic fire fighting drills should be carried out to instruct operators in the specific hazards involved and the proper emergency actions to ensure maximum safety for personnel and integrity of equipment. Operating personnel must not endanger themselves while attempting to deal with a fire. Small scale fires may be tackled with hand-held extinguishers, but major fires should be dealt with from a distance using deluge systems, firewater monitors, hose reels and fire hoses. The Safety Officer is responsible for periodic checks of fire fighting and safety equipment to ensure they are in full working order. Safety items noted as faulty, non-functional or missing should be immediately reported to the Safety Officer. ▲ CAUTION: Company policies and procedures for confined space entry must be followed. Entry to all process vessels requires a Confined Space Entry Permit. As a minimum, any vessel to be entered must be isolated, purged of gas, and the air quality within confirmed acceptable before entry. Failure to confirm acceptable air quality and monitoring of air quality during the entry could result in serious injury or death.
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18-22
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Follow lockout/Tagout procedures when checking pumps that could start automatically at anytime. When preparing pumps for maintenance, exercise caution. Avoid contact with liquids in pumps. 18.7.2
Diesel Fire Pump Before entering the Fire Pump Building 273-BLD-001, the operator must verify proper ventilation is present in the building. When test running Diesel Fire Pump 273-P-101 hearing protection must be worn when in the building while the Diesel Fire Pump is in operation. A pressure relief valve prevents overpressure of the firewater header system. When filling the Fire Pump Diesel Day Tank 273-TK-101, use proper grounding to prevent sparking from static build-up. Leave sufficient space in the tank to allow for thermal expansion. If diesel fuel is spilled in the area or a leak develops, the spill must be taken care of immediately to prevent exposure to personnel and to eliminate a slipping hazard. Apply oil absorbent material to diesel spill. Wear appropriate chemical resistant gloves and approved eye protection when handling diesel contaminated materials. During flammable gas releases up wind of the Diesel Fire Pump, the diesel will not be started until the atmosphere is determined free of explosive gases and safe to start. Hot surfaces are present while the Diesel Fire Pump is in operation and for a considerable time after the diesel is shut down. Gloves must be worn to avoid burns from hot surfaces. Appropriate PPE should be worn when checking oil and water levels (gloves and goggles must be worn at all times).
18.7.3
Fire Monitors and Hydrants High-pressure firewater is provided at fire monitors, which can injure an operator if the monitors are not used properly. When testing or inspecting fire monitors, verify the high pressure water stream does not spray directly on to instrumentation or electric motors.
18.7.4
Inergen® Fire Suppression System Inergen® gas is considered safe when exposed to humans but is heavier than air and displaces oxygen in a confined space, potentially causing suffocation. The gas primarily comprises nitrogen and argon gas, which may cause irritation to some personnel following exposure. Personnel must evacuate a building where Inergen® gas is released to avoid possible exposure risks. The cylinders are secured in a container located on the outside of the building. Caps protect the cylinder valve from damage when the cylinder is disconnected from the system, whether the cylinders are full or empty. Exposure to high pressure gas releases must be avoided. High
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18-23
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
pressure gases can permeate into skin exposed to the exhausting jet stream from a cylinder. Very low temperatures may occur when high pressure gas discharges from a cylinder so skin contact must be avoided to prevent frostbite. Cylinders must not be stored in hot locations or in direct sunlight. 18.7.5
Carbon Dioxide System Carbon dioxide (CO2) displaces oxygen when the gas is released. Personnel must be evacuated from the building if CO2 is released into the HVAC control cabinet. Skin exposure should be avoided when handling CO2 cylinders. High-pressure gas can permeate into the skin and cold temperatures present near rapidly discharging gas from cylinders can cause frostbite. Cylinders are secured in a bracket to the side of the HVAC control cabinet to prevent accidental movement. Protective caps are used when the cylinder is not in service. Cylinders must not be stored in hot locations or direct sunlight.
18.7.6
VESDA None.
18.8
PRE-STARTUP CHECKS Before placing the Unit in service for the first time or after shutdown for maintenance, confirm the Unit is ready for startup. Refer to Section 18.5, Unit Conditioning.
18.8.1
Verify minimum utilities (fire water, instrument air and electric control power) are available and commissioned to all necessary users.
Confirm that all safety equipment is in place and is fully operable.
If startup follows maintenance, confirm repairs have been completed and Unit has been pressure tested, purged as required and is ready for startup.
Confirm vent and drain valves are in their normal operating positions. Verify Lock Open/Lock Close and process manual valves are in their proper positions and locked.
Confirm transmitters and controllers are ready for service.
Diesel Fire Pump The following steps are performed before starting up the Diesel Fire Pump 273-P-101:
Verify all tubing and piping connections are secured.
Verify diesel fuel tank is full.
Confirm utilities are available (e.g., instrument air, electricity, and firewater).
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18-24
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.8.2
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Check oil level in diesel engine and add oil if level is low.
Verify radiator water level is full.
Verify battery water level is at full level.
Verify battery charger is in service.
Verify valve line-up is correct.
Verify pressure safety valve (PSV) is properly aligned.
Verify housekeeping is performed in Diesel Fire Pump building.
Flush firewater header to grade, if work was performed on header.
Verify battery condition is acceptable.
Notify supervisor of any problems encountered.
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
Fire Monitors, Hydrants, and Headers Checks are performed before placing a fire monitor, hydrant, or header in service:
Verify ease of movement of fire monitor, left/right and up/down.
Verify no leaks on equipment.
Verify spray nozzle setting is in mid-range setting.
Verify when water is applied that water stream does not contact delicate instrumentation or electric motors.
Verify hydrant valves are fully closed.
Verify post indicator valves (PIV) indicated the proper setting, open or closed.
Notify supervisor of any problems encountered.
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18-25
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.8.3
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Deluge Systems Deluge systems are either in service, tripped or out of service. When the system is being prepared for service, perform the following:
18.8.4
Verify piping and connections for system are secure.
Verify firewater pressure is available up to system.
Verify proper valve alignment to applicable Deluge System.
Verify sufficient instrument air pressure is available at Deluge System.
Notify supervisor of any problems encountered.
Verify that the LFAP is operational.
Verify heat detectors and smoke detectors are operational.
Verify area around heat detectors and smoke detectors are free of obstructions.
Notify supervisor of any problems encountered.
Inergen® Fire Suppression System A system that has full cylinders is essential when preparing this system for service.
18.8.5
Verify cylinders are full as indicated at local pressure gauges.
Check local fire alarm panel for power.
Verify proper valve alignment for system.
Verify proper bank of cylinders is selected, Main or Reserve.
Verify box containing selector valves is locked closed.
Verify smoke and heat detectors are operational.
Verify area around smoke and heat detectors is free of obstructions.
Notify supervisor of any problems encountered.
Carbon Dioxide System When preparing the CO2 system for service, verify it has a full cylinder by weighing the CO2 cylinder and verifying the weight matches the weight stamp on the CO2 bottle.
Check local fire alarm panel for power.
Verify Auto/Manual operation switch is in the Auto position at the LFAP Verify proper valve alignment for system.
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18-26
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.8.6
18.9
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
GASCO PROJECT NO. 5228 Agreement No 13522801
Rev. 1
VESDA
Verify the VESDA™ panel is operational.
Verify that the internal fan is operational.
Verify that the filter is clean.
INITIAL STARTUP Initial startup refers to the first time a piece of equipment is placed in service. This can include commissioning and startup after a major repair or overhaul.
18.9.1
Diesel Fire Pump Reference: Diesel Fire Pump, 273-P-101 controller manual, document number 25179-200V1A-MPGF-00017, Diesel Controller Data for a detailed description of operation During the initial startup of the Diesel Fire Pump, run the pump long enough to reach operating pressure and temperature. Record readings at normal operating temperature and pressure, then shut down and service the diesel engine according to the manufacturer's instructions. While the Diesel Fire Pump is in operation, the operator is to perform the following:
Initial turnover of engine is performed by: Setting engine speed at minimum Placing Auto/Off/Manual switch to Off position Verifying fuel supply is off Turning engine over by pressing Crank on Battery 1 or Crank on Battery 2 push button Verifying that oil pressure increases to normal operating pressure Verifying that there are no leaks; water, oil, diesel fuel, or exhaust system Open fuel supply Starting diesel and run at idle speed until coolant temperature is 66°C or higher Listening for unusual noises or excessive vibration Stop diesel engine and make corrections or adjustments, if necessary
When initial turnover is completed, start Diesel Fire Pump and perform the following: - Verify diesel engine reading is within established parameters. - Verify firewater discharge pressure is at 12.4 barg.
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
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ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Record performance information for reference. 18.9.2
If conditions are abnormal (e.g., excess noise, high vibration, leaks) stop Diesel Fire Pump, Notify supervisor of problems encountered.
Fire Monitors, Hydrants, and Headers Perform the following basic checks before placing a fire monitor, hydrant, or header in service.
18.9.3
Check no debris is present in spray nozzle. Verify smooth operation of valve to fire monitor and hydrant. Verify smooth operation of fire monitor nozzle and proper spray pattern. Ensure locking bolts function properly when setting fire monitor. Verify system is free of air by venting at high point vent. Verify that no equipment leaks are present.
Notify supervisor of problems encountered.
Deluge Systems The following basic checks are performed before placing the system in service for initial startup, which is the precursor to placing it in the Ready mode for operation.
18.9.4
Verify sufficient firewater pressure is available up to deluge system isolation valve. Check sufficient instrument air pressure is available in the system. Verify that the system resets properly. Verify no leaks are present when the system is reset and ready for service. Inspect spray nozzles and ensure that they are free of obstructions.
Verify that the local fire alarm panel is in service.
Notify supervisor of problems encountered.
Inergen® Fire Suppression System Basic checks are performed before starting up this system, which includes opening cylinder isolation valves and switching on the sensors monitoring the relevant area under this protection.
Verify power system indicates system in service at local Fire Alarm Panel. Verify system is not leaking gas. Verify smoke and heat detectors are in service. Verify that the air conditioning unit in the storage container is operational.
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-28
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.9.5
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Verify lights in the storage container are working properly. Verify all pressure gauge readings are correct. Notify supervisor of problems encountered.
Carbon Dioxide System Performed the following before starting up this system:
18.9.6
Verify power system indicates system in service at local Fire Alarm Panel. Weigh CO2 cylinder and verify weight is within +/- 10% of cylinder fully charged weight stamp on the CO2 bottle. Verify smoke and heat detectors are in service. Verify Auto/Manual operation switch is in the Auto position at the LFAP. Notify supervisor of problems encountered. Verify pressure gauge reading on CO2 cylinders is correct.
VESDA Performed the following before starting up this system:
Test each of the pipe sectors. Verify power system indicates system in service at the local fire alarm panel. Verify power to the VESDA™ panel. Notify supervisor of problems encountered.
18.10
NORMAL STARTUP
18.10.1
Diesel Fire Pump After the initial startup checks have been completed and no problems were found, the pump will be placed in standby. The pump does not run continuously. Reference: Diesel Fire Pump, 273-P-101 controller manual, document number 25179-200V1A-MPGF-00017, Diesel Controller Data for a detailed description of operation. The operating mode of the Diesel Fire Pump 273-P-101 is selected with the Auto/Off/Manual mode switch. It is normally placed in Auto to allow it to start when needed. The operator can manually start the diesel fire pump locally by selecting Manual and pressing the Start button. The Diesel Fire Pump should only be run when sufficient outflow/minimum flow protection is present on the firewater header to prevent the pump running deadheaded.
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-29
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.10.2
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Inergen® Fire Suppression System Verify the following:
18.10.3
Power is available to the local Fire Alarm Panel. Trouble lights are not illuminated. Sufficient pressure is available at the gas cylinders.
Carbon Dioxide System Verify the following:
18.10.4
Power is available to the local Fire Alarm Panel. Trouble lights are not illuminated. Auto/Manual operation switch is in the Auto position at the LFAP Sufficient pressure is available at the gas cylinders.
VESDA Verify the following:
Power is available to the local Fire Alarm Panel. Trouble lights are not illuminated.
18.11
NORMAL OPERATION
18.11.1
Diesel Fire Pump Reference: Diesel Fire Pump 273-P-101 controller manual, document number 25179-200V1A-MPGF-00017, Diesel Controller Data for a detailed description of operation During normal plant operations, the Diesel Fire Pump is in standby mode and is not running. When making operator rounds, perform the following checks:
Verify position of the Auto/Off/Manual selector switch to ensure the pump is in Auto mode
No alarms are present at the Diesel Fire Pump local alarm panel
Verify housekeeping is acceptable in Fire Pump Building 273-BLD-10
When the diesel drive is in operation, additionally confirm the following: Correct rpm is indicated on control panel gauge. Running oil pressure is noted. There are no unusual noises.
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-30
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.11.2
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
There are no leaks of water, oil, diesel fuel or exhaust. Engine jacket water temperature is within range. Notify supervisor of problems encountered.
Shut down Diesel Fire Pump, if problems are noted during operation.
Rev. 1
Fire Monitors, Hydrants and Headers Perform the following when making operator rounds:
18.11.3
Verify applicable post indicator valves (PIV) are properly aligned.
Verify fire monitors are preset in potentially trouble areas.
Positioned in the direction of where trouble may occur. Spray pattern preset to power cone setting. Ensure hydrant valves are fully closed when not in service.
Verify hydrant valves are fully opened when in service.
Check soil around hydrant is not eroded.
Notify supervisor of problems encountered.
Inergen® Fire Suppression System Perform the following at the local Fire Alarm Panel:
18.11.4
Verify power is available at local Fire Alarm Panel.
Verify Auto/Manual changeover switch is in the applicable position:
Auto, when system is in normal configuration for service Manual, when cylinders are being changed (swapping empty cylinders for full ones) Check alarms that are not present on the panel.
Notify supervisor of problems encountered.
Carbon Dioxide System Perform the following at the local Fire Alarm Panel:
Verify power is available at local Fire Alarm Panel.
Check Auto/Manual operation switch is in the Auto position at the LFAP
Notify supervisor of problems encountered.
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-31
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.11.5
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
VESDA Perform the following at the VESDA™ panel:
Verify power is available.
Verify power is available at local Fire Alarm Panel.
Notify supervisor of problems encounter.
18.12
NORMAL SHUTDOWN
18.12.1
Diesel Fire Pump Reference: Diesel Fire Pump, 273-P-101 controller manual, document number 25179-200V1A-MPGF-00017, Diesel Controller Data for a detailed description of operation The Diesel Fire Pump, 273-P-101 is stopped at the local control panel.
18.12.2
Press the Stop push button at the local control panel.
Verify diesel engine stops.
Check the following after the pump is stopped and engine cooled down:
Check oil level and top up to fill mark, if necessary. Check radiator water level and top up, if necessary. Verify that there are no leaks of water, oil, diesel fuel or exhaust. Prepare equipment for maintenance as directed by supervisor as applicable.
Notify supervisor of any problems.
Fire Monitors, Hydrants, and Headers Fire monitors, hydrants, and headers are not shut down unless maintenance is required. Use Lockout/Tagout procedures for any maintenance activities for the monitors or hydrants.
Verify applicable post indicator valves (PIV) are closed.
If required, prepare hydrant for repair as follows, after isolating the relevant header section:
Verify applicable hydrant valve is closed. Check hose connection valve is closed, if applicable. Remove hose connection cap. Open hydrant valve fully. Open hose connection valve, if applicable.
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-32
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.12.3
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
If required, prepare fire monitor for repair as follows, after isolating the relevant header section: Open fire monitor valve. Drain water to suitable location. Prepare equipment, fire monitor or hydrant for maintenance, if necessary. Notify supervisor of any problems
Inergen® Fire Suppression System Isolation of the Inergen® Fire Suppression System can be accomplished several alternate ways:
18.12.4
Close cylinder isolation valves.
Close Main/Reserve isolation valves.
Turn power off local to the Fire Alarm Panel.
Carbon Dioxide System
18.13
Isolate or shutdown the Carbon Dioxide System by removing the solenoid valve.
EMERGENCY OPERATING CONDITIONS Emergency operations are performed when there is a malfunction that prevents equipment from functioning as it should due to equipment failure or damage.
18.13.1
Diesel Fire Pump Reference: Diesel Fire Pump, 273-P-101 controller manual, document number 25179-200V1A-MPGF-00017, Diesel Controller Data for a detailed description of operation If automatic operation of the Diesel Fire Pump fails, manual operation can be achieved as follows.
Verify adequate water level in firewater storage tanks is available.
Ensure valves are in their correct position.
Check safety relief devices are in service.
Verify oil level in diesel is full or fill as necessary.
Confirm diesel pump starts as follows: Verify Auto/Off/Manual selector switch is in Manual position. Press either Crank on Battery 1 or Crank on Battery 2 push button.
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-33
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
Observe diesel starts. 18.13.2
Inergen® Fire Suppression System If there is a fire and the system does not function automatically, manual override is achieved using the Extinguishing System Manual Release switch located in each area of protection.
18.13.3
Carbon Dioxide System If the Carbon Dioxide (CO2) System does not function properly when needed, manually override it using the release valve on the system to deliver CO2 to the protected area.
18.14
REFERENCES The following are reference documents used to produce this section of the manual:
Ansul Inc., Material Safety Data Sheet, Inergen® Gas
Ansul, Inc., Material Safety Data Sheet, Carbon Dioxide
25179-000-M0X-0000-F0001, Equipment List
25179-273-MPD-MPGF-M0001, Mechanical Data Fire Water Pump
25179-273-MUD-MPGF-M0001, Mechanical Data Fire Water Pump Diesel Engine Driver
25179-273-M50-0000-Y0001, Unit 273 Firewater Overall Block Flow Diagram
25179-200-V1A-MPGF-00002, Diesel Fire Pump General Arrangement Drawing/Interface and Connection Schedule
25179-200-V1A-MPGF-00003, Fuel Tank Drawing (650) Gallons
25179-200-V1A-MPGF-00004, Acoustic Enclosure General Arrangement
25179-200-V1A-MPGF-00005, P&ID
25179-200-V1A-MPGF-00006, Diesel Fire Pump Data Sheets Filled In
25179-200-V1A-MPGF-00007, Diesel Fire Pump Curve
25179-200-V1A-MPGF-00008, Engine Data Sheet and Drawings
25179-200-V1A-MPGF-00009, Fire Pump Engine Drawings
25179-200-V1A-MPGF-00011, Low Fuel Level Switch Data
25179-200-V1A-MPGF-00017, Diesel Controller Data
25179-200-V1A-MPGF-00018, Coupling Data
25179-200-V1A-MPGF-00019, Exhaust Muffler and Flexible Connection Drawing
25179-200-V1A-MPGF-00020, Cooling Loop and Fuel System Diagram
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-34
ASAB-2 OPERATING MANUAL CHAPTER 18 FIREFIGHTING UNIT 273 ABU DHABI GAS INDUSTRIES LTD. (GASCO)
18.15
GASCO PROJECT NO. 5228 Agreement No 13522801
COMPANY DOC. 999-ZX-E-09060-C18 DOC. NO. 25179-000-GPP-GSX-00011C18
Rev. 1
25179-200-V1A-MPGF-00021, Pump Cross Sectional Drawing/Bill of Materials
25179-200-V1A-MPGF-00028, Lubrication List
25179-200-V1A-MPGF-00029, Packing, Shipping, Preservation, Handling and Storage Proc.
25179-200-V1A-MPGF-00035, Installation, Operation and Maintenance Manual
25179-000-J0R-0000-J1305 Rev 000, Alarm Summary Report
ATTACHMENTS 25179-273-M60-0000-F0101
Unit 273 – Fire Water System
25179-273-M60-0000-F0102
Unit 273 – Fire Water
25179-273-M60-0000-F0103
Unit 273 – Fire Water
25179-273-M60-0000-F0104
Unit 273 – Fire Water
25179-273-M60-0000-F0106
Unit 273 – Deluge Systems
25179-273-M60-0000-F0107
Unit 273 – Inergen Fire Suppression System
25179-273-M60-0000-F0108
Unit 273 – Carbon dioxide System For HAVC Control Cabinet
25179-273-M60-0000-F0109
Fire Water Pump
Snamprogetti Drwg no: 161-GD-B-86061
Fire / Utility Water Storage Tanks
Snamprogetti Drwg no: 173-GD-B-86750
Fire Water System
ELECTRONIC DOCUMENTS ARE CONTROLLED. ANY PRINTED COPY WILL BE UNCONTROLLED AND MAY BECOME OUTDATED Bechtel_Firefighting Unit 273_R1Bechtel_Firefighting Unit 273_R1.doc
18-35
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