Specification For Fire and Gas Detection System PDF
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PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-060117S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 2 of 8
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PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-060117S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 3 of 8
1. General This specification describes the modifications to the Project Specification, A3CA-06011-FP-002, Specification for Fire & Gas Detection System, for the PTTLNG Jetty Development and LNG Receiving Terminal Project to be built at Map Ta Phut industrial estate, Rayong, Thailand. Instruction contained in this specification such as "Add", "Modify" and "Delete" shall be interpreted as follows: Add Add : The requirement requirement shall be read as a continuation continuation of the Project Specification. Specification. Modify : The requirement in the Project Specifica Modify Specification tion shall be replaced by the requirement in this specification. Delete : The requirement Delete requirement in the Project Specification Specification is no longer effective.
2. Modifications to Project Specification A3CA-06011-FP-002 2.1 Article 1.1 General (Modify) The Vendor shall have full responsibility for furnishing a complete and workable system including all equipment and services to meet the functional requirements and the reference project specifications, codes and standards specified herein. (Modify) Compliance by the Vendor with with the requirements of this specification does not relieve the Vendor of of his responsibility of supply equipment, which is of proper design and construction, fully suited for all specified conditions. conditions.
2.2 Article 1.3 System Overview (Modify) All Buildi Buildings ngs FGS systems systems shall shall be desig designed ned per per NFPA NFPA 72 as well as all a appl pplica icable ble Build Building ing Codes. Vendor to confirm during detailed design. Vendor’s Vendor’s design shall require PTTLNG/PMC agreement and approval before before proceeding. (Modify) The FGS is one of the instrument systems which form part of the overall Integrated Control System (ICS). (ICS). Testing of all interfaces between between FGS and other other parts of ICS is detailed in specification 7S92-06011-CS-TS-003 "Specification for Process Control System ". This specification specification defines also also the boundary for the FAT and SIT.
PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-060117S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 4 of 8
2.3 Article 2.1 Project Specifications and Drawings (Modify) 7S92-06011-CS-TS-001
Instrument Design Criteria
7S92-06011-CS-TS-007
Specification for Control Panels Integrated Control and Safety System Philosophy Specification for Process Control System Specification for Safety Instrumented Systems Fire Protection Philosophy ( Design Criteria) Area Classification Classification Drawings, Electrical
7S92-06011-CS-TS-002 7S92-06011-CS-TS-003 7S92-06011-CS-TS-004 7S92-06011-FP-TS-002 7S92-06011-0300-EL-001
2.4 Article 3.0 Abbreviations Abbreviations (Modify) FIT
Factory Integration Integration Test (carried out by PCSI (Vendor) (Vendor)))
2.5 Article 4.1 Equipment Location (Modify) The system shall be installed in air conditioned buildings where the climatic conditions shall be as prescribed in 7S92-06011-C 7S92-06011-CS-TS-001, S-TS-001, Instrument Design Criteria. Criteria .
2.6 Article 5.1 Equipment Location and Design Criteria (Modify) The AIR will have HVAC equipment to maintain environmental conditions. The Vendor shall shall confirm whether special conditions are required.
2.7 Article 5.3.1 Power Supplies (Modify) a) Power supplies shall be provided in accordance with specification 7S92-06011-CSTS-004, Specification for Safety Instrumented Systems (SIS).
PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-060117S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 5 of 8
(Modify) (Modify) b) FGS cabinets shall be fed from redundant redundant 230 VAC – UPS instrument distribution boards.
1
2.8 Article 5.3 Earthing System (Modify) 5.3.2 For cabling and Earthing concepts, concepts, refer to 7S92-06011-CS-TS-001 7S92-06011-CS-TS-001 “Instrument Design Criteria”.
2.9 Article 5.6 Time Synchronization Synchronization (Modify) The FGS shall be synchronized with the plant master clock system (GPS) (GPS)..
2.10 Article 5.7 FGS Graphics Specification (Modify) The FGS graphic specification shall be developed by Vendor during detailed design and shall follow the PCS graphic specification.
2.11 Article 6.4 System Cabinets (Modify) 6.4.6 FGS cabinets shall comply with 7S92-06011-CS-TS-007 7S92-06011-CS-TS-007 “Specification for Control Panels”.
2.12 Article 6.8 Cabinet Mounted Panels (Modify) Vendor shall shall ensure that all cabinet mounted panels are equipped with a common lamp test pushbutton.
2.13 Article 6.10 Local Fire & Gas Control Panel (Modify) The LFGCP shall be capable of controlling all alarm functions for buildings that being
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PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-060117S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 6 of 8
controlled. 2.14 Article 7.1 General (Modify) FGS Cause and Effect Diagrams (By CONTRACTOR) : 7S92-0601 7S92-06011-PC-DS-205 1-PC-DS-205 Piping and Instrument Instrumen t Diagrams (P&ID) for Fire Fighting : 7S92-06011-1000-FP001~012/ 301~304 Fire and Gas Plan Drawings : 7S92-06011-1300-CS-360 SHE requirements requirements in the Project Specification, Specification, Annex J, section 12.
2.15 Article 7.3 CCR FGS Control Panels (Modify) (Modify) 52” touch screen LCD monitor also be provided in the 7.3.1 A FGS Panel Fire Station Building, this facility will be forMimic "ReadPanel shall Only" shall purposes.
1
2.16 Article 8.1 General (Modify) The provisional quantities and location of detectors are shown on Fire and Gas Detection Detection Plan drawings 7S92-A1-06011-1300-CS-360. 7S92-A1-06011-1300-CS-360.
2.17 Article 8.4 Smoke Detectors (Modify) (Modify) 8.4.2 Smoke detectors detectors shall be be either fixed head head or reflection reflection type. Smoke detectors detectors shall not be provided provided for indoor indoor cable trays. The The Vendor shall ensure optimum operation of the detector system.
2.18 Article 9.1 General (Modify) This section describes equipment which is activated by the FGS. The Vendor shall shall ensure that all interfaces between the FGS and following equipment are correctly engineered.
PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-060117S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 7 of 8
2.19 Article 11.5 Consumables and and Spare Parts (Modify) The Vendor shall shall provide up to the completion of commissioning all consumable items as defined in the project specification.
2.20 Article 11.6 Documentation Documentation (Modify) The Vendor shall include in his tender any restriction relating to the application of this system for the specific TUV Class requirement.
2.21 Article 13.1 General Requirements Requirements (Modify) Vendor shall shall be responsible for ensuring directly or indirectly that a fully integrated test of the FGS is performed. This test shall simultaneously incorporate every different compon component ent (s) to prove functionality and reliability, simulating site logistics and environmental conditions where possible.
2.22 Article 13.3 System Staging (Modify) (Modify) shall maintain a detailed logbook covering the following areas: Vendor shall - Material deficiencies - System activity - System problems and resolutions resolutions - System testing (Modify) Load taking devices shall be simulated at the input input /output tterminals. erminals. The Vendor is is to advise the environmental conditions under which the burn-in takes place (i.e. ambient temperature and humidity). h umidity).
2.23 Article 14.0 FGS Block Diagram (Add) Refer to Attached drawing, 7S92-A3-06011-1300-CS-023, System Block Diagram for
PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-060117S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 8 of 8
Fire & Gas Detection System (FGS)
3. Attachment
7S92-A3-06011-1300-CS-02 7S92-A3-0 6011-1300-CS-023, 3, Rev. 0, 0, System Block Diagram for Fire & Gas Detection System (FGS) A3CA-06011-FP-002, A3CA-06011-FP-002, Rev. 4, Specification for Fire & Gas Detection System
PTTLNG Company Limited Jetty Development and LNG Receiving Terminal Project
Front End Engineering Design
Specification for Fire & Gas Detection System Document Number: A3CA-06011-FP-002
4
9 Jul 07
Rev
Date
Issued to EPC Contractor Description
VM VM By
GH GH
GH GH
Checked
Approved
Acknw’ed by PTT
Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
Rev. 4
Table of Contents Page
1.0 SCOPE............. SCOPE....................... ....................... ....................... ..................... ....................... ....................... ...................... ....................... ................ .... 1 1.1 Gener General................. al............................... .................................. ........................................ .................................. .................................. ......................1 ..1 1.2 Objec Objectives.............. tives............................ .................................. .................................. .................................. ....................................... .....................2 ..2 1.3 System Overview.......................... Overview.............................................. .................................. .................................. ................................2 ............2 2.0 CODE CODES S AND STAN STANDARDS DARDS .......... ..................... ..................... ....................... ....................... ....................... .................... .......3 3 2.1 2.2 2.3
Project Specifications and Drawings.......... Drawings .................... ..................... ................. ................ ..................... ................ .....3 3 Local Codes and Standards............................................................................4 Internati Inter national onal Standards................... Standards...................................... ................................. .................................. ...............................4 ...........4
3.0 ABBREVIATIONS................... ABBREVIATIONS................................ ......................... .......................... .......................... ......................... .................... ....... 4 4.0 CLIMATIC CLIMATIC AND SITE DATA ........... ..................... ....................... ....................... ..................... ....................... .................. ...... 5 4.1 Equi Equipmen pmentt location location ............................ ................................................ .................................. .................................. ...........................5 .......5 4.2 Area Classification Classification ..................... ........... ..................... .................... .................... ..................... ................ ................. ..................... ...........5 .5 5.0 GENERAL GENERAL REQUI REQUIREME REMENTS NTS.......... .................... ..................... ....................... ....................... ....................... .................. ...... 5 5.1 Equipment Locations and Design Criteria .................... ......... ..................... ................. ................. .................. ........5 5 5.2 Reliability and Redundancy.............................................................................6 5.3 Electr Electrical ical Requirem Requirements ents ........................... ............................................... .................................. .................................. .....................6 .6 5.4 System Spareage and Loading Criteria...........................................................7 5.5 Standard Hardware Hardware and Software ..................... ........... ..................... .................... .................... ..................... ............... .....7 7 5.6 Time Synchron Synchronizati ization on ........................... ............................................... .................................. .................................. ........................7 ....7 5.7 FGS Graphics Graphics Specific Specificatio ation n ........................... ............................................... .................................. .............................7 ...............7 6.0 HARDWARE HARDWARE REQUI REQUIREMENTS REMENTS ......... .................... ...................... ....................... ....................... ....................... .............. .. 8 6.1 Gener General................. al............................... .................................. ........................................ .................................. .................................. ......................8 ..8 6.2 Main Fire and Gas Control Panel....................................................................8 6.3 SER Hardware........ Hardware...................... .................................. .................................. .................................. .................................. ....................9 ......9 6.4 PLC System................... System...................................... ................................. .................................. .................................. ..........................10 ............10 6.5 Engi Engineer neering ing Workstatio Workstation n .......................... .............................................. .................................. .................................11 ...................11 6.6 6.7 6.8 6.9 6.10 6.11 6.12
MIMIC MIMI C Panel........................................ Panel...................................................... .................................. .................................. .......................11 .........11 Main Distribution Frame (MDF) Cabinets ..................... ........... .................... ................. ................. ................ ......11 11 Cabinet Mounted Panels...............................................................................12 Input / Outputs Outputs Structure...................... Structure......................................... ................................. .................................. ........................12 ....12 Local Fire & Gas Control Panel.....................................................................15 Earth Leakage Detection...............................................................................16 System Segregatio Segregation......... n....................... ................................. .................................. .................................. .............................17 ..........17
7.0 FUNCTIONA FUNCTIONAL L REQUI REQUIREMENTS REMENTS ........... ...................... ....................... ....................... ...................... ................... ........17 17 7.1 Gener General................. al............................... .................................. ........................................ .................................. ..................................17 ....................17 7.2 Overv Overview.... iew.................. .................................. .................................. ................................. .................................. ................................17 .................17
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Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
7.3 7.4 7.5 7.6 7.7
Rev. 4
Human Machine Interface Human Interface (HMI) (HMI) ........................... ............................................... .................................. ...................19 .....19 Seriall Communic Seria Communication ations s ............................ ................................................ .................................. .................................21 ...................21 Interfaces Inter faces with with Other ICS Systems Systems ........................... ............................................... .................................. ................21 ..21 Complian Comp liance............... ce............................. ................................. .................................. .................................. ....................................22 .................22 Diagnosti Diag nostics cs .......................... .............................................. .................................. .................................. .................................. ...................23 .....23
8.0 DETECTION DETECTION SYS SYSTEMS TEMS .......... ..................... ....................... ....................... ...................... ....................... .......................23 ...........23 8.1 Gener General................. al............................... .................................. ........................................ .................................. ..................................23 ....................23 8.2 Flammable Gas Detection.............................................................................23 8.3 Fire Detectio Detection n ............................ ................................................ .................................. ................................. .................................25 ..............25 8.4 8.5 8.6
Build Buildings.................... .................................. .................................. .................................. .............................26 ...............26 LNG ings........................................ Leakage Detection................................................................................27 Toxic Gas Detection Detection................ .............................. .................................. .................................. .................................. ......................28 ..28
8.7
Detectors Detec tors Voting Voting ........................... ............................................... .................................. ................................. ..............................28 ...........28
9.0 ACTIVATIO ACTIVATION N SYSTE SYSTEMS MS ........... ...................... ....................... ....................... ...................... ....................... ..................... .........28 28 9.1 Gener General................. al............................... .................................. ........................................ .................................. ..................................28 ....................28 9.2 Water Spray / Deluge / Foam Systems ..................... .......... ..................... ................. ................. ................... ......... 28 9.3 Audible Alarm and Beacon Systems Systems .................... .......... ..................... ................. ................ ..................... .............. ...29 29 10.0 CONFIGURATION AND PROGRAMMING EQUIPMENT ............. ........................... .............. 30 10.1 Gener General................. al............................... .................................. ........................................ .................................. ..................................30 ....................30 10.2 Editi Editing.. ng................. ............................. ................................. ....................................... .................................. .................................. .......................30 ...30 10.3 Con Configura figuration tion ............................. ................................................ ................................. .................................. ..................................31 ..............31 11.0 PROJ PROJECT ECT REQU REQUIRE IREMENTS MENTS .......... .................... ..................... ....................... ....................... ....................... ................ .... 31 11.1 FGS Scope of supply and Services...............................................................31 11.2 Proje Project ct Execution................... Execution....................................... .................................. .................................. .................................. .................31 ...31 11.3 Stand Standardiz ardizatio ation.......................... n.............................................. .................................. .................................. .................................31 .............31 11.4 Description and System Sizing Data .......... .................... ..................... ................. ................ ..................... .............. ...32 32 11.5 Cons Consumabl umables es and Spare Spare Parts ............................ ............................................... ................................. ......................32 ........32 11.6 Docum Documenta entation. tion............... ............................ .................................. .................................. .................................. ...............................32 ...........32 11.7 Software and Software Documentation Documentation ..................... .......... ..................... ................. ................. ................... ......... 32 12.0 ENGINEERING AND TRAINING SERVICES ............. ........................... ......................... ................... ........ 33 13.0 INSP INSPECTIO ECTION N AND TESTIN TESTING G .......... .................... ..................... ....................... ....................... ....................... ................ .... 33 13.1 Gener General al Requirem Requirements................. ents............................... .................................. ........................................ ...............................33 ...........33 13.2 Man Manufactu ufacturin ring g Test ............................ ................................................ .................................. .................................. .........................33 .....33 13.3 System Staging............ Staging.......................... .................................. .................................. .................................. .................................34 .............34 13.4 Factor Factory y Acceptanc Acceptance e Test (F.A.T.) (F.A.T.) ........................... .............................................. ................................. ...................34 .....34 13.5 System Integration Testing (SIT)...................................................................36 13.6 Site Acceptanc Acceptance e Test........................................... Test......................................................... .................................. ...........................36 .......36 14.0 FGS BLOCK DIA DIAGRAM GRAM .......... ..................... ....................... ....................... ...................... ....................... .......................36 ...........36
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Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
1.0
Rev. 4
SCOPE 1.1
General This specification defines the minimum technical requirements for the design, materials, fabrication, assembly, inspection, testing, and performance, of a complete fire and gas detection system for the PTT LNG Receiving Terminal Project (hereafter described described as the TERMINAL). TERMINAL). The Fire & Gas Control Control System ((FGS) FGS) shall include all necessary appurtenances, accessories, auxiliaries and controls as required for a fully operable integrated system. The technical design, hardware, configuration and functionality of the FGS shall generally comply with the following:
NFPA 72 - “National Fire Alarm Code” Code” and NFPA 59A - “Standard for the Production, Storage, and Handling of Liquefied Natural Gas (LNG). Human Machine Interface (graphical presentation) will be carried out via the Mimic panel in the main control room, VDU operator console, the PCS and in combination with hardwired switch panels. The Contractor shall have full responsibility for furnishing a complete and workable system including all equipment and services to meet the functional requirements and the reference project specifications, codes and standards specified herein. The fire & gas detection system shall be capable of interfacing to other systems via both hard-wired and soft soft links, as described below. For the critical signals, the interfacing utilized will be hard-wired, but for the alarm, status, and non-critical signals, the interfacing utilized will be soft-link.
Emergency Shutdown System (ESD) Process Control System (PCS) HVAC System PA/GA System Fire Protection System (e.g. Water Spray Spray or Foam Systems)
Compliance by the CONTRACTOR with the requirements of this specification does not relieve the CONTRACTOR of his responsibility of supply equipment, which is of proper design and construction, fully suited for all specified conditions. 1.1.1
The FGS shall as a minimum contain: -
*Fire Sirens and Horns *Detectors *Programmable *Programmabl e Logic Controller *Isolators and field termination (housed in MDF cabinets) *System Cabinets and Cables *HMI Displays *Switch Panels (for control panels mounting) *Cabinet mounted Engineering Engineering workstation *A SER system including: -Printer -Desk top Engineering Workstation (SER and FGS use) 1 of 36
Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
-
Rev. 4
Main Fire and Gas Control Panel (MFGCP) – PLC Based Architecture Local Fire and Gas Control Control Panel (LFGCP) – Addressable, Addressable, Microprocessor Based
The Building FGS system shall be a complete addressable fire and gas detection System.
1.2
1.1.2
FGS equipment equipment for the Jetty Area and and Truck Loading Loading shall shall be integrated integrated with with the main FGS via remote I/O.
1.1.3
Deleted
Objectives Objective s
1.2.1
The principal principal objectives objectives of of the Fire Fire and Gas System System (FGS) are:The protection of personnel. The protection of environment. The protection of equipment, plant and structures.
1.2.2
The FGS shall achieve these objectives by:-
Detecting, at an early stage, the presence of flammable and toxic gases. gases.
-
Detecting incipient fire and the presence of fire.
-
Providing automatic and / or facilities facilities for manual activation of the fire protection system, as required.
-
Initiating signals, signals, both both audible audible and and visible, visible, as required, warning of the detected hazards.
-
1.3
Provide sequence of event recording for analysis purposes purposes
System Overview All Fire and Gas safety critical functions shall be implemented implemented with independent independent instrumentation instrumentatio n and shall be hardwired hardwired to the FGS system logic. FGS sensor signal processing and system logic (PLC's) shall be geographically distributed as individual FGS sub-systems in various process and utility plant located Field Auxiliary Rooms Rooms (FAR's), Auxiliary Auxiliary Instrument Rooms Rooms (AIR’s (AIR’s)) and the CCR. Dedicated F&G control panels shall be provided in the CCR, which will comprise of VDU's and a hard wired wired switch panel. panel. The control panels shall be integrated with with the Mimic panel. The VDU's will graphically display the geography of the site, presenting alarm conditions via a variety of hierarchical screens (e.g. total overviews and specific zoned locations). The control cabinets shall also provided with hard wired switches to initiate FGS protection and alarm systems where appropriate. The control and monitoring system for the FGS shall be PLC based. It shall form the basis of each sub-system and shall communicate with:
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Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
Rev. 4
the CCR FGS FGS control panels (VDU / printer) for display, recording and transmission of receipt of the status of fire and gas devices.
the CCR FGS mimic mimic panel for display of the status status of fire and gas devices devices throughout the TERMINAL.
the CCR FGS control panels (hard wired switches) for safety critical functions.
other sub-system sub-system FGS PLC's PLC's for tthe he initiation initiation of alarm and and protection protection systems etc.
All Buildings Buildings FGS system systems s shall shall be designe designed d per NFPA 72 as well well as all applicabl applicable e Building Codes. CONTRACTOR to confirm during detailed design. CONTRACTOR’s design shall require PTTLNG/PMC agreement and approval before before proceeding. For main alarm overview and hardware layouts, the LNG complex shall be split into geographical geographic al areas. These shall shall be: The process and utilities areas The Truck Loading area The Jetty Unloading area Berth #1 The Jetty Loading area Berth #3 The building areas All Instrumented Protective Function (IPF) initiators shall have independent independent instrumentation instrumentatio n and shall be hardwired to the FGS system logic. The FGS is one of the instrument systems which form part of the overall Integrated Control System (ICS). (ICS). Testing of all interfaces interfaces between between FGS and other parts of ICS is detailed in specification A3CA-06011-270-70005 "Specification for Process Control System ". This specification specification defines also the boundary for the FAT and SIT.
2.0
CODES AND STANDARD STANDARDS S The equipment shall comply with the latest issue of the following documents:2.1
Project Specifications Specifications and Drawings A3CA-06011-270-70001
Instrument Design Criteria
A3CA-06011-270-70003
Specification for Control Panels Process Control and Safety Instrumented Systems Philosophy Specification for Process Control System Specification for Safety Instrumented Systems Fire Protection Philosophy ( Design Criteria) Area Classification Classification Drawings, Drawings, Electrical
A3CA-06011-270-70004 A3CA-06011-270-70005 A3CA-06011-270-70006 A3CA-06011-1000-FPR-001 A3CA-A1-06011-0300-EL-001
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2.2
Rev. 4
Local Codes and Standards Applicable Thai Thai Codes and Standards
2.3
International Standards National Fire Protection Agency (NFPA (NFPA)) NFPA 59A (2006): NFPA 70:
Standard for the the Production, Storage, and Handling of Liquefied Liquefied Natural Gas (LNG) National Electric Codes
NFPA 72: NFPA 496:
National Fire Alarm Code Purged Enclosures for Electrical Equipment
International Electrotechnical Commission (IEC) IEC 60529:
Degrees for Protection Provided by Enclosures (IP Code)
British Standards Institution EN 1473(1997): 1473(1997): Installation and Equipment Equipment for Liquefied Natural Gas – Design of Onshore Installations
3.0
BS 5445
Specification of components systems (Parts 1 - 2 - 7 - 8).
of
automatic
fire
detection
BS 5839
Fire Detection and Alarm Systems in Buildings
BS 6020
Instrumentation for the detection of combustible combustible gases.
ABBREVIATIONS AIR CCR CCTV CPU DCS EDP EPCC EMC ESD FAT FAR FIT FGCP FGS HMI ICS IPF IPS I/O IS LAN LED
Auxiliary Instrumen Instrumentt Room Centra Centrall Control Room Closed Circuit Television Television Central Processing Unit Distributed Control System Emergency Depressurizing Depressurizing Engineering Procurement Construction Commissioning Commissioning Contractor Contractor Electro Magnetic Compatibility Compatibility Emergency Shutdown Factory Acceptance Test Field Auxiliary Room Factory Integration Integration Test (carried out by PCSI) Fire and Gas Control Panel Fire and Gas System Human Machine Interface Integrated Control and Safety System Instrumented Protective Function Instrumented Protective System Input/Output Intrinsically Safe Local Area Network Light Emitting Diode
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Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
LEL MCP MCR MDF MOS MOES NFPA PCS PCSI PLC
Lower Explosive Limit Manual Call Point Main Control Contro l Room Main Distributed Distribu ted Frame Maintenance Override Switch Maintenance Override Enable Switch National Fire Protection Association Process Control System Process Control System Integrator Programmabl Programmable e Logic Controller
Rev. 4
RDAS SAT SER SIS SIT SIGTTO SOV TCS TSO UPS VDU
4.0
Rotating Equipment Equipment Data Acquisition System Site Acceptance Test Sequence of Events Recorder Safety Instrumented Instrumented System System Integration Integration Test (carried out by PCSI) Society of International Gas Tanker and Terminal Operators Solenoid Operated Valve Terminal Control System Tight Shut Off Un-Interruptible Power Supply Visual Display Unit
CLIMATIC AND SITE DATA 4.1
Equipment location The system shall be installed in air conditioned buildings where the climatic conditions shall be as prescribed in A3CA-06011-270-70001. A3CA-06011-270-70001. It is a requirement that the systems shall be capable of operating for prolonged periods at temperatures up to 40 °C.
4.2
Area Classification Classification All instrumentation shall be designed and installed installed in compliance with area classification. For reference reference see see area electrical classification classification drawing. drawing.
5.0
GENERAL REQUIREMENTS 5.1
Equipment Locations and Design Criteria FGS electronic hardware which is connected to the process plant located equipment shall be housed in non-hazardous Auxiliary Equipment Rooms (AIR), FAR or CCR. The AIR will have HVAC equipment to maintain maintain environmental environmental conditions. conditions. Contractor shall confirm whether special conditions conditions are required. required.
The
AIRs will be employed to house the majority of the Integrated Control and Safety System (ICS) hardware, which will be interconnected to the CCR and remote control rooms by fiber optic cable.
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Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
Rev. 4
The following locations will contain AIRs for the installation of FGS equipment PLC cabinets:
5.2
-
Jetty Substation
-
Truck Loading CR
-
CCR – AIR
Reliability and Redundancy
5.2.1
Reliability FGS are required to have high high availability, availability, reliability and and integrity. A system reliability analysis shall be provided for the systems part of scope. The analysis shall include Mean Time Between Failure figures and availability values of every module employed employed in the system.
5.2.2
-
Mean Time Between Failures (MTBF) - > 80,000 hours
-
Mean Time to Repair 4 hrs. (Max)
-
Availability
- > 99.99 %
Redundancy FGS shall be designed to avoid unexpected failures of software and or hardware and provide a level of of high availabil availability. ity. These requirements requirements lead to redundancy of system hardware. Details for PLCs are described described in paragraph 6.0.
5.3
Electrical Requirements Requirements 5.3.1
Power Supplies c) Power supplies shall be provided in accordance with specification specificat ion A3CA06011-270-70006 and d) FGS cabinets shall be fed from dual 230 VAC – UPS instrument distribution boards. e) Separate sets sets of redundant redundant power power supplies supplies are required for: - System related hardware - Field related hardware f)
5.3.2
Status indication indication and and fault alarm alarm of all power supply supply modules modules inside the cabinets shall be provided.
Earthing System For cabling and Earthing concepts refer to A3CA-06011-270-70001 A3CA-06011-270-70001 “Instrument Design Criteria”.
5.3.3
The Contractor Contractor shall ensure ensure that the earthing is in full compliance compliance with the ICS Vendor specific earthing requirements requirements..
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5.4
System Spareage and Loading Criteria 5.4.1
Spareage Requirements Requirements Spare = Installed I/O - Used I/O * 100 100 % Used I/O Spare hardware and space shall be included as follows:-
Rev. 4
a) Minimum 20 % fully connected and functional spare I/O shall be available follow ing plant commissi shall be evenly distributedfollowing throughout thecommissioning. system. oning. This spareage shall b) Multi-pair cables terminating in MDF cabinets cabinets shall include include at least 20 % unused pairs which shall be connected in sequence to spare terminals along with used pairs. The Multipair spares spares shall be available available post plant plant commissioning c) Additionally, systems systems shall include include wired rack rack / slots to enable system system I/O to be increased by 20 % after plant commissioning (cards shall not be installed). It shall be possible possible to add such hardware without without shutting down the system and without causing process upset. 5.4.2
Loading Criteria a) After plant commissioning, commissioning, microprocess microprocessor or based system capacity, capacity, RAM and communications bus loading shall not exceed 70 %, of the maximum capability. b) Power supply units shall be sized sized such that they they are only loaded loaded to 50 % of their capacity (inclusive projected expansion). expansion).
5.5
Standard Hardware and Software FGS systems shall employ standard hardware and software of the Vendor's own design and supply. Vendor supplied hardware and software shall be TUV approved.
5.6
Time Synchronization The FGS shall be synchronized with the plant master clock system. Subsystem clocks shall be synchronized at a suitable frequency to ensure that the SER resolution time time stamping is is not compromised. compromised. The necessary interfaces interfaces to the the master clock system shall be provided. provided.
5.7
FGS Graphics Specification The FGS graphic specification shall be developed by CONTRACTOR during detailed design design and shall shall follow the the PCS graphic graphic specification. specification. The number of pages should cover the whole plant area (ie. example, process, utilities, building, truck loading, jetty jetty area, etc). Moreover, PTTLNG/PMC shall agree and approve before proceedin p roceeding g.
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6.0
Rev. 4
HARDWARE REQUIREMENTS 6.1
General The fire and gas detection system for the TERMINAL shall consist of a PLC based system for the Process Units with an integrated integrated MFGCP consisting o off graphics display, display, networking networkin g communication system. Each building or occupied shelter shall include a
dedicated addressable microprocessor based LFGCP complete with local audible notification notifi cation system. The MFGCP shall communicate with the plant emergency evacuation notification notification system via the PAGA system. Activation of critical functions between systems (i.e. HVAC, Fire Protection Equipment, etc) shall be via hard wired I/O from f rom the MFGCP System. Trip signals from any LFGCP shall be hard wired to the MFGCP for processing and trip activations. No trip signals to critical critical systems shall be allow allowed ed directly from the LFGC P. The FGS shall be based on PLC technology and carry TUV approval. The overall FGS shall comprise of individual stand alone sub-systems, located in equipment rooms, which are connected to FGS equipment in the main control building AIR. Each FGSfail sub-system shall communicate via serial communication by means of a dedicated safe, self checking and fully redundant redund ant bus system. The FGS equipment shall monitor its own hardware and all field circuits which are not “self revealing" (normally de-energized) and the system shall annunciate unrevealed signals to PCS. The system shall as a minimum annunci annunciate ate all faults at PLC card level. All FGS detectors shall be individually individually connected to the FGS logic system and shall operate with either analog 4-20 mA inputs or digital volt free contact inputs, which shall facilitate individual monitoring monitoring of FGS detectors i.e. continuous line monitoring. monitoring. Where required interface modules shall be used between field instrumentation and PLC I/O (e.g. Isolation barriers and signal conditioning conditioning units). units). 6.2
Main Fire and Gas Control Panel MFGCP located in the CCR, shall include a networked command center with a graphics display for communicating to the facility operator status of all the fire and gas detection devices devices and fire protection system system inputs for the TERMINAL. The panel shall monitor the fire, gas, LNG leak, and trouble alarms from individual building LFGCPs and display the information on its LCD screen. In addition to the control and monitoring capabilities, MFGCP shall also function as a data acquisitioner and communicate all its pertinent data to PCS via a data link (e.g. Modbus protocol via RS485). The collected data will then be configured and displayed (by others) on the dedicated F&G screen among the workstations located in the CCR. The MFGCP shall be supervised around the clock. A permanent record of all alarms received shall be maintained maintained at the MFGCP and in in the PCS Historian database. database. The MFGCP shall also detect all changes in status of monitored points, poin ts, provide event 8 of 36
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annunciation, and actuate fire protection systems as required related to the TERMINAL. The MFGCP shall receive signals from manual fire alarm call stations site-wide via the network. A signal shall shall be transmitted transmitted based based on the location location of the MAC MAC station activated through sirens located outdoors and flashing strobes located indoors in the high noise building or area, all over the site to inform personnel of the emergency
condition and its location. In addition, initiation of a Manual Alarm Call (MAC) (MAC) shall result in an alarm being raised at the PCS HMI, no other automatic action should take place at this point. The MFGCP shall include an approved releasing module for inert gas extinguishing system activation and other other fire protection systems systems (as applicabl applicable). e). The MFGCP shall monitor flammable or toxic gas and LNG leak alarm input signals. The MFGCP shall monitor field fire and gas monitoring devices and all manual release pushbuttons, and status notification of solenoid valves and pressure switches of water spray and foam systems in the process areas (as applicable). The MFGCP shall be programmed to shutdown or operate in re-circulation mode the building HVAC system during a fire or gas condition, as defined in the detailed engineering engineerin g phase. The FGS system shall provide the following response capabili capabilities: ties:
Fire and gas control panel indication indication
Subsequent fire alarm conditions to include include at least least 5 previous events starting starting in order with the highest priority.
Inert gas extinguishi extinguishing ng system activation
Water spray system activation from pressure switches
Shutdown and/or re-circulate re-circu late HVAC and electrical power (except for life life safety purposes)
Activation of PA/GA PA/GA Tone Generator and strobes units in in local local buildings buildings
Activation of of plant emergency communication communication system system and and activation activation of of sirens, and PA/GA and strobes, site-wide.
6.3
SER Hardware All necessary SER hardware and software shall be designed and integrated in the FGS.
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6.4
Rev. 4
PLC System 6.4.1
General The FGS PLC System redundancy shall be achieved by the fault-tolerant
design of the system logic solver. All components shall be redundant such that no single point of failure will deem the system inoperable The FGS PLC shall be provided with redundant: -
Power supplies
-
CPU's Internal communication communication paths/busses
-
External communication communication paths/busses
-
Input/output cards
To prevent faults within a rack, affecting the performance of the bus or any other rack, the electronics of each rack shall be optically isolated from the PLC highway communication bus. To achieve the required level of availability and allow online maintenance, it sha ll be possible to remove and replace any of the cards from the PLC without effe cting its operation. 6.4.2
Central Processing Unit (CPU) Each CPU shall have its own power supply, clock, RAM / EPROM memory, and parallel interface for access for programming units. PLC CPU's shall shall run synchronously. synchronously. It should be possible to remove or replace a single clock without affecting operation. The clocks should synchronize automatically at power up of the system or after replacement of a single clock card.
6.4.3
Memory The program memory contained in each CPU shall be “Flash EEPROM”. Timers should be memory resident. They should be started, stopped, reset and scanned scanned under program control. control. The timers timers shall be capable capable of adjustment between tenths of seconds, minutes, and hours. For pulse inputs to the IPS, the PLC scan rate shall be such that the minimum pulse length is at least two cycles. For every workstation, programming facilities shall be provided to transfer the FGS functionality into memory.
6.4.4
System hardware The FGS PLC hardware shall be housed in system cabinets. They shall contain I/O cards, power supplies, terminations, trunking, panel wiring, system cable sockets etc. 10 of 36
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6.4.5
Rev. 4
Diagnostics. FGS hardware shall shall be provided provided with self self diagnostic facilities. Diagnostic
data and results available from the self testing mechanism shall be displayed on the PCS workstation. Failure messages shall be available in the system cabinets for the maintenance maintenance engineer. engineer. The messages shall contain sufficient information for defective defective card card replacemen replacement. t. Apart from the message display, full diagnostics shall be accessible through the screen of the engineering output of status shall ional also be available on the engineering workstation. workstation. Input Live /update the functional funct logic diagrams shall assist in system system troubleshooting. troubleshooting. An overview overview of system failure messages and diagnostics is required. required. 6.4.6
System Cabinets Cabinets FGS cabinets shall comply with A3CA-06011-270-70003 “Specification for Control Panels”.
6.5
Engineering Workstation 6.5.1
The main FGS system cabinet located located in the CCR CCR AIR shall contain a HMI HMI for engineering and maintenance. maintenance . A desktop PC engineering workstation shall be provided in the CCR. The engineering work station station shall have access to the complete FGS system.
6.5.2
FGS System shall shall be capable capable of of communicating communicating with the the PC workstations workstations for performing the following functions: -
On-line & Off-line configuration configuration
-
Application Programming
-
On-line Human Interface
-
Standard & Custom display development
-
System diagnostics display
-
Auto documentation
Security features must exist in the system to prevent inadvertent and unauthorized access. access. 6.6
MIMIC Panel Panel 6.6.1
6.7
The Mimic Panel in the CCR for the FGS system system shall be a 52” LCD LCD monitor. The display will utilize the graphical style to indicate the status and alarm for the plant wide area. The graphics will be the same same as on the VDU operator statio station. n. The MIMIC display will normally show only an overview of the plant FGS information.
Main Distribution Frame (MDF) Cabinets MDF cabinets shall be used for marshalling field cables to system cables and are located in the FARs and AIR. MDF cabinets will also house iinterfac nterface e components such as: -
Power Supplies
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Isolator amplifiers
-
Proximity amplifiers amplifiers
-
Detector Interface modules
Rev. 4
6.8
-
Terminals
-
Cable - and wire supports
Cabinet Mounted Panels Dedicated switch panel(s) shall be provided, designed for flush panel mounting in the relevant section of the main control cabinet in the CCR. The panel(s) shall be supplied with back lit switches and be logical grouped together by area zone. CCR control panels FGS related switches shall be directly wired to the main PLC cabinet located in the MCR AIR. Contractor shall ensure that all cabinet mounted panels are equipped with a common lamp test pushbutton. 6.8.1
Maintenance Override Panel A maintenance override panel shall be provided. provided.
6.8.2
Deluge, Foam and Siren Activation Activation of fire fighting f ighting systems is normally a local operation. The activation of fire fighting systems shall be capable from the PCS/FGS VDU operator control panels. The panel shall also contain back lit activation / resetting switches switche s for plant located located beacons and audible alarms. The panel shall be be designed such that its layout is representative of the FGS area zones. Deluge and foam activation switches shall require double action. action.
6.9
Input / Outputs Structure 6.9.1
General Fire and gas detection instrumentation that are classified as “Safety critical I/O circuits” shall be designed "fail-safe" and implemented such that the system automatically reverts to the least hazardous condition in case of failure of system logic, inputs, power sources etc. This requirement shall be realized by applying a "de-energize to trip" design. To avoid revealed failures, in cases where non "fail-safe" elements are used, energize to trip redundancy with self checking and / or comparison techniques shall be used to determine loop short circuit and open circuit failures. Signal types belonging belonging to this group are: -
Manual Call Points
-
Proximity switches (for FGS function)
-
Smoke Detectors
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- Heat Detectors Where required, intrinsically safe galvanic isolation shall be provided
between the FGS and field signals. 6.9.2
Signal Categorization Categorization 24 V(dc) floating power supply should be galvanically separated from the logic components. A FGS loop shall always be powered from f rom the FGS power supply. Voltage free output signals communicating with other systems shall be powered by the receiving system (e.g. PCS, etc). Power supply fusing for I/O cards and output circuits shall be separately fused, based on logic groups (Logic groups defined by the Process Unit area zones). For redundant redundant I/O cards, cards, each rack shall be separately fused. circuiting of one output shall not affect other outputs.
Short
Contractor to ensure that FGS interface signals to PCS / SIS shall be correctly powered and segregated It shall be possible to remove I/O cards without disturbing the signal wiring. The card connection can be either via plug and socket or terminals System I/O can be divided into: a)
safety critical
b)
non safety critical signals.
a)
Safety critical signals are those that assure the the safety integrit integrity y of the plant. Signals to / from the system shall shall either be via redundant redundant fail safe serial data links or hardwired. Typical safety critical signals are:
b)
-
Deluge and Horn manual initiators.
-
Detectors and SOV in and output signals.
-
Trip initiating signals from other ICS equipment equipment . Machinery protection FGS related-sig related-signals. nals.
-
Plant visual and audible alarm initiators.
-
Maintenance Maintenan ce Override (MOS) enable inputs.
Non critical critica l signals to / from the the system may may either be via serial data links or hardwired. hardwired. Non safety critical signals i.e.: alarms, indication, indication, sequence of events (SER), reset switches and maintenance override switches shall comply with the following: -
Hardwired non safety safety critical circuits shall be arranged arranged so that probable failure modes e.g. cable/termination faults, power supply loss, etc. will not cause shutdown or prejudice the systems safety integrity.
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-
Rev. 4
Signals routed via serial data links shall not cause shutdown or
prejudice the systems safety integrity. Communication of non safety critical signals between the FGS logic system (sub-system FAR PLC's) and the CCR (FGS control panels) shall be routed via fault tolerant fiber optic BUS. 6.9.3
Input Modules Analogue input modules shall be designed to accept a variety of signals. LED indicators shall be provided on the front of the circuit board, visibly showing the status of the field input circuits. Input card design criteria:-
Selectable to act as passive or active power source
-
Floating from earth.
-
Open circuit detection
-
24 VDC.
-
Short circuit proof.
-
Megger proof (500 V).
The input card shall be capable of providing power for the following types of input signals: -
Analogue transmitters (1-5 Vdc and or 4-20 mA)
-
Contacts
-
Low current signals
-
Pulse signals
Where redundant analog input signals are implemented, the PLC shall initiate an alarm if there is more than 2% difference between input signals being read by the processor processor from each signal in the redu redundant ndant pair. When a 2% deviation alarm exists and a card failure has not been detected, the analog input closest to the trip setpoint shall be used by the processor for logic functions. functions. In the event event of an input input card or processor processor failure, failure, the remaining correct analogue input shall be used for safeguarding logic functions and transmission transmission to the PCS. Input module rrequirements equirements for the PLC shall support “Line monitoring function, end of line resistance”. The I/O shall be the type that supports this function. All transmitter input signals used used for logic processing shal shalll be transmitted to the PCS via serial communication. communication. Redundant Redundant inputs for one transmitter shall be considered as one signal to be transmitted to the PCS. The modules shall be key coded, relative to type, to prevent accidental damage to the printed circuit boards in the event of incorrect connection. The location and type of card shall be clearly indicated on the equipment.
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6.9.4
Output Modules
Rev. 4
6.9.4
Output Modules Output card design criteria :-
LED indicating indicating output energized. energized.
-
Selectable to act as passive or active power source
-
Floating from earth.
-
Open circuit detection
-
Potential free contacts, contacts, rated rated 24 24 VDC, 1 A. (goldplated (goldplated or hermetically hermetically sealed)
-
Megger proof (500 V).
The output card shall be capable of providing power for the following types of output signals: -
Digital 24 V(dc) max. 10 VA).
-
Serial data link
Lamps 24 V(dc) output for MOS Horns and beacons For digital outputs to SOVs, power to the field shall be provided from the MDF field power supplies. The modules shall be key coded, relative to type, to prevent accidental damage to the printed circuit boards in the event of incorrect connection. The location and type of card shall be clearly indicated on the equipment. Output module requirements for the PLC shall support “Line monitoring function, end of line line resistance”. The I/O shall be the type type that supports this function.
6.10
Local Fire & Gas Control Panel The Local Fire and Gas Control Panel (LFGCP) shall have the similar functions as the MFGCP and act independently to detect all changes in status of monitored points, provide event annunciation, display status and provide acknowledgement of all events occurring within its monitored building. The LFGCP shall be capable of controlling all alarm functions within each building. Unoccupied buildings with only a few fire detection devices may be added to the nearby addressable signal circuit by terminating at a local junction box inside the building. The building audible warning and flashing strobes units shall operate as a general fire alarm condition throughout the building of incidence. System Requirements Requirements The LFGCP shall accept, process and evaluate the following types of signals: Addressable analog smoke detectors (buildings) (buildings)
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Addressable heat detectors (buildings) (buildings) Addressable manual fire alarm stations (MAC) in buildings
Inert gas gas extinguishin extinguishing g system system pressure pressure operated switch contact (buildings) (buildings)
Sprinkler system water flow alarm pressure switch (buildings)
Water spray systems water flow alarm pressure switches
Circuit fault monitoring of building signaling circuits shall include the following characteristics Signaling line circuit open condition
Signaling line circuit short condition
Signaling line circuit ground condition condition
Excessive electrical "noise" on the signaling line circuit
Ability to to identify identify the location of short and open circuit conditions conditions
Ability to to identify identify the location of short short and ground conditions
Detector or device missing conditions
Improper device type at a specific address
Un-configured device at an address
Multiple devices at the same address
The system shall provide point point isolation by a single point point or group group of points. The system shall ignore signals signals from input input devices when isolated. isolated. The system shall shall annunciate and remain in a trouble state while any fire f ire alarm device is isolated. The system shall provide provide identification identification of of point type, location location and status. Each addressable and analog fire alarm device shall have a field assigned unique minimum 32 character device device location location message. The system shall provide addressable addressab le indicating circuit modules used to activate local notification appliances in each building. The system shall provide addressable indicating circuit modules used to activate local notification appliances in each building.
6.11
Earth Leakage Detection Earth leakage leakage detection shall be provided. It shall consist consist of a detection/alarm detection/alarm system, which continuously monitors and alarms if one of the connected circuits circuits has an earth fault.
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This feature shall be implemented for each field f ield power supply feeder to a single ffield ield circuit. Upon earth fault detection a local local lamp shall illuminate illuminate inside the MDF MDF cabinet and a common alarm shall be transmitted to the PCS. An important purpose of the earth leakage detection system is to identify identify solenoid solenoid faults in the field. 6.12
System Segregation The design of the FGS structure shall enable maintenance, testing and card replacements to be carried out without disturbing other FGS functions. Plant area zones shall have their control and I/0 processing hardware separated and segregated. segregated. Signals shall be distributed distributed throughout throughout the the I/O processing hardware such that common mode failures are minimized. Similarly, redundant cards shall be located in different racks. Segregation and assignment of signals during the design phase shall include sufficient margin to finally provide the required level level of spareage.
7.0
FUNCTIONAL REQUIREMENTS 7.1
General The functional design of FGS system shall be based on the following project documents:-
FGS Cause and Effect Diagrams (By CONTRACTOR)
-
Piping and Instrument Diagrams (P&ID) for Fire Fighting
-
Fire and Gas Plan Drawings
-
SHE requirements requirements in the Project Specification, Specification, Annex J, section 12.
The FGS shall be operational operational at all times, times, even during during total plant shut-down. shut-down. All FGS detectors, alarms and associated equipment shall be electrically supplied by an un-interruptible power supply (UPS). Fire protection system shall have the capability of being initiated both manually and automatically via the fire detection systems. 7.1.1
Functional Structure Each protective sub-system shall operate independently from other subsystems. If safety relevant signals have to be routed from one subsys subsystem tem to another, they shall be hardwired hardwired or routed routed over the FGS System Bus Bus and not routed via PCS communication communication link. link.
7.2
Overview 7.2.1
Detection System The function of the detection system is to promptly identify any abnormal conditions resulting from a fire, or gas (LNG) escape and to provide signals to other sub- systems to initiate warning alarms and protective actions.
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Suitable flammable gas, toxic gas, low temperature, and fire detectors shall be installed in strategic strateg ic locations throughout throughou t the plant. The Fire and Gas detectors shall have integral signal processing and switching capability to provide either 4-20 mA signal and / or volt-free contact signal inputs to the Logic System. 7.2.2
System Logic The Logic functionality of the FGS system shall be achieved by the FGS PLC's software. The purpose of of the system logic is to process input signals from the detection system and carry out the following actions : Initiation of selective alarm and display information in the CCR and plant areas. Enable manual or automatic activation of fire protection systems, The logic shall be designed to minimize spurious alarms and trips whilst maintaining system integrity. The logic system shall provide an input to a FGS SER, and shall interface with the FGS HMI console (PCS) (PCS) and other FAR FGS PLC's. Where required a hard wired interface shall be provided between the FGS PLC and the IPS PLCs within each FAR.
7.2.3
Plant Alarm Alarm and Warning System (audible and visual) The FGS shall interface to the plant emergency communication system, activation of sirens/horns/strobes, and PA/GA site-wide plant alarm and warning system. The plant alarm and warning system is required and shall be engineered as an independent module of the FGS system, its purpose is to receive inputs and generate audible and visual alarms to a variety of output devices. Sufficient pushbuttons / switches shall be provided, but not limited to the following functionality: Site(s) Fire Alarm (Activation) Site(s) Fire Alarm (All clear) Zone(s) Gas Alarm (Activation and Silence) Zone(s) Gas Alarm (All clear)
7.2.4
Alarm Presentation All FGS alarm signals shall be presented on the CCR FGS and Fire Station Building control panels, logged and printed via the SER facilities. f acilities. In line with the functional structure, the following types of alarms shall be presented: High level (LEL) flamma f lammable ble gas gas High High level (LEL) flamma f lammable ble gas 18 of 36
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Fire (initiated from heat, fire, smoke detectors) LNG Leak detection Manual Call Points Common zone alarms shall be presented on the FGS VDU control panels Common zone alarms applicable to package units shall similarly be presented. An alarm management management system shall be developed developed which achieves the following objectives: Minimize Minimi ze the number of active alarms Maximize the information contained in the alarms Obtain effective presentation of alarms All new buildings buildings e.g. Service building, building, Warehouse, Warehouse, AHs, FARs, Substations, Substations, etc. shall have indoor detectors and fire panels. 7.3
Human Machine Interface Interfac e (HMI) 7.3.1
CCR FGS Control Panels The HMI comprises of VDU graphic displays and hard wired switch panels. The HMI shall be be the primary iinterface nterface for all FGS FGS related activities. activities. The Mimic panel shall replicate overview displays from one of the VDU stations. All FGS protection systems and plant audible and visual alarms, shall be initiated initiate d from the control panels. The VDU graphic layout shall shall be a geographical representation of the whole site which shall be split into three main areas, i.e. : The process / utility area The Jetty Loading/Unloading Loading/Unloading areas The Truck Loading area The Buildings area Vendor installations which only provide common alarms, (i.e. BOG compressor, analyzer houses, sub-stations, etc.) shall be graphically identified as an individual zone. Under normal conditions, an alarm shall be presented by a small open box; an alarm situation will change the open box into a solid box. Symbols for gas alarms shall distinguish between High and High High alarms. Individual detector status including analogue values shall be shown on a lower graphic display and alarm summary status. A FGS control panels shall also be provided in the Fire Station Building, this facility will be for "Read Only" purposes.
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The FGS VDUs are part of the PCS system, and as such shall be implemented as part of the PCS scope. The VDU for the t he FGS shall be a dedicated set, serving only the FGS monitoring, status and control. The operati operation on for PCS control on on this panel is prohibited. prohibited. Additionally, the VDU for the FGS (PCS operator station) shall support the multi-screen function (at least two), where one monitor shall be utilized as a operator screen and other monitor shall besame usedprocessing as a MIMICunit). for the FGS for this project (these twothe monitors will share the 7.3.2
Maintenance Override Switches (MOS) The TERMINAL maintenance override philosophy shall be in accordance with existing PTT practice. MOS shall be provided for all FGS inputs with an exception for the following signals: - Manual trip switches - Limit / Proximity switches Maintenance override switches for FGS shall be implemented on basis of fire protection areas. areas. In general, the the/ Sounders MOS shall and be configured co nfigured to prohi prohibit bit the activation of Fire Sirens / Beacons Beacons the Fire water pump(s), pump(s), however alarms of circuits under MOS MOS condition shall generate alarms in the CCR. To apply a MOS function function the following following two steps are required:: required:: - Step one the Maintenance Maintenance Override Override Enable Switch Switch (MOES) is activated. (see for details a) below) - Step two the MOS MOS is set. (see for details b),c) and d))
a) Maintenance Override Enable Switches (MOES) Hardwired, back-lit Maintenance Override Enable Switches (MOES) shall be integrated on the PCS console. One MOES shall be provided per cause and effect fire zone. The MOES is hardwired into the FGS logic, the operator has the facility to de-activate an override override regardless the status of the PCS or communication communication link. The "MOES and lamp lamp shall give an overview of all the maintenance overrides that are currently activated b) Maintenance Override Switches (MOS) MOSs shall be configured in the PCS and connected to the FGS via redundant serial links. MOSs shall be accessed via the PCS graphic displays. PCS MOS override signal shall be accepted by the FGS logic only when the MOES is in the enable position.
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The "MOS set" indication lamps shall be located on the PCS console to indicate the MOS status and shall have three states: - Off
No MOS is on
- On
A MOS is on but the trip initiator is in normal state (process condition is healthy).
- Flashing
A MOS is on and the trip initiator is in trip state.
Output from the PCS to set MOS's shall include FGS software which prevents more than one MOS being activated act ivated per Process Unit Area zone. c) MOS activation The PCS sends a "MOS requ request” est” via the serial serial link to the the IPS. The IPS determines if the use use of the MOS is permitted. This is only permitted permitted if the "MOES” is in the enable position and only one MOS is selected for a particular Process Unit Unit Area Area zone. If both both criteria criteria are fulfilled, the maintenance override is set and a "MOS set" signal is sent back from the IPS to the PCS via the serial link. If the "MOS set" signal is not received within 5 seconds after the "MOS" request", request ", then the PCS shall automatically cancel the "MOS request". The canceling of the "MOS request" shall generate an answer back alarm in the PCS to indicate to the operator that the "MOS request" has been denied. d) MOS de-activating An activated and confirmed MOS can be de-activated de -activated via the PCS screen. The tag will change color from blinking red to black. 7.4
Serial Communications Communications Only standard international communication communication protocols shall be utilized. (Such as EIA RS-232-c, modbus RTU, RS-484, Ethernet E thernet TCP/IP) Internal communication between manufacturers hardware may deviate from the above. Serial Links shall not be utilized to pass critical safety related - and/or controls signals between between different systems. Special attention shall be be given to the testing of serial links during the FAT. Loss of one serial link within the redundant system structure shall not lead to any malfunction.
7.5
Interfaces Interface s with Other ICS Systems 7.5.1
Process Control System (PCS) The PCS shall be used to display and annunciate all FGS status information.
7.5.2
In addition to the the above, other signals signals are required by the PCS for SER alarm displays, MOS setting and confirmation etc. Emergency Shutdown System (ESD/SIS) 21 of 36
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The FGS shall shall provide selected inputs inputs for initiating initiating ESD actions. interface to the ESD/SIS shall be hardwired outputs from the FGS.
7.5.3
The
FGS - Vendor Installed Package Equipment Interface Requirements Requirements Separate fire and gas systems (sub systems) will be provided by certain package equipment vendors (e.g. compressors, analyzer houses, substations, etc.). These systems shall be be interfaced with the the FGS system logic (PLC) within each relevant FAR. The interface shall be hardwired and will facilitate status, common alarm and command signal data transmission to the CCR. The systems shall provide the following signals to the FGS logic (PLC) within the relevant FAR, and shall be generic for all vendor fire and gas systems, - Outputs: - Common Gas detection detection alarm alarm (flammable (flammable and / or toxic) - Common Fire detection alarm - Common Heat detection alarm - Protection system activated (gaseous, deluge etc.) - System fault - Maintenance override selected / confirmed confirmed (to CCR FGS) - Inputs: Maintenance override selection (per initiator). refer to section 7.3.2 for guidance on MOS application. Package equipment vender installations which activate an automatic protective system, shall also allow for manual initiation and resetting from the CCR FGS control panels. The manual activation (from the CCR) of these package FGS systems shall only be permitted after alarm generation and evacuation times have elapsed.
7.6
Compliance The minimum requirement requirement for FGS systems are as per IEC 61511 Initiators and outputs associated with the following items shall be implemented in accordance with the IEC61511 classification: spray systems fire prevention on Compressors Compressors Compressor Compresso r shutdown -
Isolation of electrical supplies in hazardous atmospheres
Electrical instrumentation components and electronic instrumentation systems for use in hazardous areas shall be in accordance with IEC 79
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7.7
Rev. 4
Diagnostics Diagnostic tools resident within FGS (for analyzing faults) shall be provided, allowing continuous diagnostics without influencing influencing the FGS performance. The analysis shall be sufficient to identify faulty cards and define the cause of the errors
8.0
DETECTION SYSTEMS 8.1
General The number and location of detectors and their associated equipment shall be developed by CONTRACTOR during detail design and shall obtain approval from PTTLNG/PMC prior to proceeding. proceeding. The provisional quantities and location of detectors are shown on Fire and Gas Detection Plan drawings A3CA-A1-06011-1000-FP-001 and A3CA-A1-06011-1000FP-002. The detectors shall be safe for operation under ambient conditions and have vibrationproof connections. connections. The detectors shall shall be suitable for location in hazardous hazardous areas. areas. The sensors shall be built into an explosion-proof, stainless steel housing. All fire f ire and gas detectors for use in process p rocess areas shall be certified as a minimum for use in zone 1 areas. All detectors shall shall be installed installed with fire retardant retardant cable.
8.2
Flammable Gas Detection 8.2.1
General Two types of flammable gas detectors shall be used to detect flammable gases: IR point detector detector and IR open path path detector. Only IR gas detectors detectors are approved for this project because they provide rapid response to gas. I)
Point IR Gas Detectors The point IR gas detectors use the properties of hydrocarbons and other gases to absorb absorb infrared energy energy at certain certain wavelengths. wavelengths. Where point IR gas detectors are chosen, 20% LFL (Lower Flammable Limits) and 50% LFL should be used as respective thresholds to indicate low/high level gas. Point IR gas detectors shall be installed near the seals of gas compressors compres sors and hydrocarbon pumps. They shall also be provided at the air inlets (e.g. HVAC) to all buildings that have potential facing flammable gas leak.
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II) Open Path Gas Detectors The open path IR gas detectors use the same principles as the IR point detectors. A beam of light is sent sent from the transmitter transmitter to the receiver receiver where it is divided and measured at two distinct wavelengths in the infrared band, one wavelength for gas indication, the other for reference. The infrared beam beam can be projected projected over 30 to 90 m long. long. The open path IR gas detectors provide information about the average flammable flammab le gas concentration along the path. The detector will produce the same response for a 1.5 m wide plume of 50% LFL as it will for a 7.5 m wide plume of 10% LFL. Open path gas gas detectors shall be be installed around the periphery of the vaporizer area. Selection of flammable gas detectors shall be suitable for anticipated types of gas release (e.g. methane). 8.2.2
Gas Detector location The location of the gas detectors shall be defined for each individual situation, taking into account the prevailing wind direction and the presence of heavier or lighter than than air gases. The detectors detectors shall be mounted below or above above the possible sources sources accordingly. considered when appropriate.
Collecting cones may be
Point IR gas detectors shall be installed near the seals of gas compressors and hydrocarbon hydrocarbon pumps. They shall also also be provided provided at the air inlets (e.g. (e.g. HVAC) to all buildings bu ildings that have potential facing flammable gas leak. Open path gas detectors shall be installed around the periphery of the vaporizer area Flammable gas detector analogue signals are used to generate alarms from values set within the the system. Alarms shall be implemented implemented as follows:follows:Flammable gas detectors shall have 2 alarm points, 'high' (H) and 'high high' (HH). The 'H' shall be set at 20 % LEL and the 'HH' at 50 % LEL, adjustable adjus table between 0-100 % corresponding to 4-20 mA. The alarm for infrared beam type (open path) shall be in LEL-meter. Any single detector, detecting detecting flammable gas above the 'H' alarm point point,, shall initiate an alarm in the CCR and a visual alarm(s) in the local plant area. CCR alarm indications shall distinguish between H and HH values. 8.2.3
Flammable gas detectors shall shall be be typically located in the air inlet inlet of: Electrical substations located within the plant area. Field auxiliary rooms (FAR). Analyzer houses. houses. Air compressors. Air intakes of building(s) building(s) HVAC system system Flammable gas detectors shall be located inside analyzer house(s). 24 of 36
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For the above the detectors shall be arranged in a two out of two voting system. syste m. Detectors shall be mounted close together together in pairs. Each detector will have two adjustable set points between 0-100% LEL. The pre-alarm shall be obtained when either detector reaches 10% LEL. When 20% LEL, an alarm will be .activated; the fresh air intakestwo willdetectors be closedreach and the ventilation fans stopped. stopped 8.3
Fire Detection 8.3.1
General The detection of a fire in its earliest stages of development is of the greatest importance importan ce if remedial actions are to be effective. effect ive. Two principal forms of fire detection shall be employed: Human (Manual Call Point) Automatic fire detection. detection.
8.3.2
Manual Call Points (MCPs) Manual call points shall be used to communicate fire detection detection to the CCR. Manual Alarm Call Points (Alarm Stations) shall be provided as a minimum based on the following criteria:
Along rroads oads in the plant plant area area at interval not exceeding exceeding 100 m Along roads in storage storage tank area not exceeding exceeding 200 m Near or at location location having having a high risk risk such as process process equipment, equipment, valve valve manifold, jetty head Inside buildings, office entrance, entrance, canteen, canteen, warehouse, warehouse, medical, guard house, etc.
In general,totheraise Alarm Points provided at the building exitsCall to enable operators anCall alarm in an aare n emergency. Manual Alarm Call Points shall be mounted at a height height of 1.2 m above floor or grade level. level. The Alarm Call Points may be used for other accidents or situation where the attention of Main Control Room is required in accordance with established operational procedures. MCPs shall be of the push button type with a key to reset. 8.3.3
Automatic Fire Detection Automatic fire detection detection shall be achieved achieved by the following following types of of devices:Infra-red flame detectors Heat detectors
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8.3.4
Rev. 4
Ultra Violet / Infrared (UV/IR) Flame Detectors UV/IR detectors shall be solar blind and shall be applied where fast detection of hydrocarbon fire or other flammable products with a high hydrocarbon content is required The design of the detectors shall be based on the flame flicker principle, i.e.. the detector responds to the flickering effect of hydrocarbon fires and are not suitable for detection detection where smoldering occurs. Infrared flame detectors shall be installed in and around process area, on the roof of LNG storage tanks, and on the jetty head.
8.3.5
Heat Detectors Fixed temperature heat detectors are usually used inside the buildings. Rate compensated heat detectors shall be provided in the areas where smoke detection is impractical such as in the kitchen, maintenance shop, or emergency emergenc y generator room. These detectors detecto rs are designed to activate at both a fixed temperature and fast thermal rate of rise due to fire f ire growth.
8.4
Buildings 8.4.1
General All building related fire and safety facilities f acilities shall be provided in accordance with project specifications. Fire and gas sensors located in AIR's, substations and analyzer houses, etc., shall be individually connected to the sub-system FGS hardware. The Contractor shall ensure that all areas within the buildings are adequately covered with detectors. The CONTRACTOR shall shall de develop velop detectors layouts during detailed design and obtain approval from PTTLNG/PMC before proceeding.
Building protection detectors shall be displayed on a local panel at the building entry point. The LNG plant's AIR located equipment shall be protected with an early warning smoke detection system. 8.4.2
Smoke Detectors Smoke detectors detectors shall be either fixed head or reflection reflection type. Smoke detectors shall not be provided for indoor indoor cable trays. The Contractor shall shall ensure optimum operation of the detector system.
8.4.3
Combined Optical Smoke / Heat Detectors Solar blind light reflection type of fixed head type detectors shall be used for the detection of smoldering smoldering fires in buildings. They shall be installed in enclosed spaces such as laboratories, computer rooms, workshops, battery rooms, warehouses, offices, FARs etc.
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Detectors shall trigger a common alarm on the FGS control panels and in the building where fire has been detected. 8.4.4
Spot type Heat Detectors Spot type Heat Detectors shall be used in building air intakes.
8.4.5
Aspirated Early Warning Type Smoke Detectors Early warning smoke detection shall be applied to detect a developing fire in high density cabling in confined confined spaces. This type of detector detects incipient incipient smoke particles formed by overheated cable installations. installations. The typical construction of such an installation employs a detector cabinet containing detectors connected connected to sample points via sample lines. The aspirator sampling sampling system is connected connected to the detector. detector. Air samples are continuously extracted from the protected zone from intake points in the air suction pipe network. CONTRACTOR shall develop the sampling system layout and determine the number and location of detectors during detail design and shall obtain the appropriate approval from PTTLNG/PMC before proceeding. Typical areas that shall be covered by early warning type smoke detectors are:
Under elevated floors in in computer computer rooms, computer auxiliary rooms. Inside instrument auxiliary rooms, cabinets, floor cavity cavity and cable cable routes.
When smoke is detected, an alarm shall be triggered locally and in the CCR. 8.5
LNG Leakage Detection Detection a) Fiber optics (to be confirmed during detailed engineering) shall be applied along the LNG piperack sections as well as the onshore and jetty LNG containment areas. Upon detecting a low temperature due to LNG leakage, alarms shall be initiated both locally and at the CCR. b) To monitor the annular space of the storage tanks for f or potential potent ial leakage and accumulation of LNG, the tank shall be equipped with a leak detection system. This system shall be comprised of the following: A fiber optic Distributed Temperature Sensing (DTS) Technology Leak Detection Detection System shall be located throughout the annular base of each tank. Communication protocol for communication with the FGS control panels in the CCR, as well as the PCS, shall be either Modbus or Ethernet TCP/IP (to be confirmed during detailed engineering). The PCS shall be used to display and annunciate leak detection alarm points. RTD’s shall be positioned at four equally spaced locations at the bottom of the annular space as a back up to the fiber optic DTS system.
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The tank leakage detection system shall be furnished as part of the LNG tank scope of supply. 8.6
Toxic Gas Detection. Detection.
8.6.1 Oxygen Deletion 8.6.1 Oxygen depletion detection shall be provided in enclosed rooms where nitrogen is used, such as analyzer building. building. The detector shall be connected connected to the building FGS panel and a separate alarm wired to the PCS. 8.6.2
H2S detection Currently there is no H2S detection requirement. requirement. If required, these detectors shall be connected to the FGS.
8.7
Detectors Voting
Detector voting is the method to ensure that fire and gas detectors are robust against failure and false alarm. 2ooN (2 out of N; N>2) logic logic means a minimum three detectors in each fire detection zone and a confirmed fire or gas leak is based on 2 or more detection. detect ion. 1ooN (1 out of N; N>1) logic means a minimum two detectors in each fire detection zone and a confirmed fire or gas leak is based on 1 or more detection. Detectio n voting Detection voting will be used for this project. For process area 2ooN shall be employed, while in in non-process area includi including ng air intake, 1ooN shall be used. 1ooN voting logic shall also be used for f or LNG spill detectors.
9.0
ACTIVATION SYSTEMS 9.1
General This section describes equipment which is activated by the FGS. The Contractor shall ensure that all interfaces between the FGS and following equipment are correctly engineered. Fire protection systems may comprise of water spray systems, deluge systems, sprinkler systems and and foam system. Such system systems s are activated via FGS, following following signals received received from the detection systems. systems. Details of the fire protection systems systems are defined in the “Fire Protection Philosophy” document A3CA-06011-1000-FPR001. General location and type of protection systems are shown on P&ID.
9.2
Water Spray / Deluge / Foam Systems The Water Spray System is normally actuated by a fixed temperature pilot head detection system. The openin opening g of the deluge valve valve will allow water to flow into the
system piping piping and to to discharge discharge from the water spray nozzles. nozzles. Other fire and gas detectors (e.g. IR flame detectors and IR gas detectors) will also be used to detect 28 of 36
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fire or LNG release and activate the Water Spray Spray System. All spray / deluge deluge systems shall be provided with a remote operated deluge valve that may by operated from the CCR. All status signals of the water spray/deluge spray/deluge systems shall be availabl available e for display on the FGS VDU in the CCR. High Expansion Foam system shall be provided to control the possible vapor release or fire resulting resulting from a LNG spill. High Expansion Expansion Foam Concentrate Concentrate shall be stored in the Foam Bladder Bladder Tank. The foam concentrate is discharged discharged from the tank by incoming water applying pressure to the bladder. Other fire and gas detectors (e.g. IR flame detectors and IR gas detectors) will also be used to detect fire or LNG release release and and activate the Foam System. All foam systems shall be provided with a remote operated deluge valve that may by operated from the CCR. All status signals signals of the foam systems shall shall be available available for display on on the FGS VDU in the CCR. 9.3
Audible Alarm and Beacon Systems The following types of audible and visual alarms shall be provided: 9.3.1
Fire Alarms Plant fire alarms shall annunciate annunciate via motor motor driven sirens for outdoors outdoors and hooters for indoors, having an on/off modulation mode with an adjustable on time of between 3 and 10 seconds. The signal frequency shall be approximate 520 Hz, soundlevel soundlevel of at least 110 dB(A) at 1 meter In order to obtain one plant plant identical alarm system system the duration of the alarm signal shall be controlled controlled via the FGS FGS Plant Alarm & Warning Warning System. System. The alarm duration shall shall be adjustable adjustable between 1 and and 10 minutes. The "all clear" signal shall be an unmodulated, steady tone with an adjustable duration range between 1 and 10 minutes. Fire beacons shall be provided for visual fire alarm indication.
9.3.2
Flammable Gas Alarms Flammable gas alarm electronic sounders, shall annunciate by two separate frequencies in anti anti phase, having having a mark space ratio of 1 :1, cycle time: time: 1 second, frequencies 2000 Hz and 1000 Hz, with a sound level of 120 dB(A) maximum at 1 meter The duration of the of the alarm signal shall be controlled via the FGS with adjustable timing between between 1 and 10 minutes. Upon acceptance of the alarm (via the silence pushbutton) in the CCR, the modulated signal shall continue for an other 30 seconds then automatically stop. Pressing the the silence silence pushbutton pushbutton from the CCR shall not silence flammable gas alarms where gas is still detected.
Pressing the local alarm reset pushbutton shall silence its associated audible alarm without without time delay. delay. 29 of 36
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Flammable gas beacons shall be of strobe type t ype and colored blue. The "all clear" gas alarm shall be a continuous tone of not less than 2 minute duration at a frequency frequency of 2000 Hz . The timing is set via the the FGS and fully adjustable between 1 and 10 minutes. 9.3.3
Toxic Gas Alarms For the generation of toxic gas alarms (if required), the audible alarms and beacons shall be designed in accordance with the flammable gas alarms. The toxic gas beacons shall be of strobe types and colored Amber / yellow.
9.3.4
Smoke Alarms Smoke alarm electronic sounders sounders shall annunciate annunciate by an interrupted tone having a mark space ratio ratio of 1:1, cycle time: 2 seconds, frequency frequency 1000 Hz, with a sound sound level of at least 105 dB(A) at 1 meter meter
10.0
CONFIGURATION AND PROGRAMMING EQUIPMENT 10.1
General For the purpose of FGS configuration the latest technology portable PC shall be provided. It shall be possible to prepare system configurations off-line using the engineering workstation. For the purpose of logic testing and logic diagram diagram production a software devel development opment package shall be provided. Configuration equipment equipment shall be:
10.2
-
Capable of being plugged in, or removed from the CPU's whilst they are operation, without without causing causing any disturbance
-
Have a full diagnostics package with complete annotation for any program listing.
-
Password protected.
Editing The editing system should be capable of generating :-
Memory contents lists.
-
Logic diagrams.
-
Input / output list.
-
Floppy disk programmed. programmed.
in
I/O forcing It should be possible to relocate blocks of instructions in memory by using delete / move and insert instructions. 30 of 36
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10.3
Rev. 4
Configuration Configuration Configuratio n should be organized as follow:- Outputs are always conditional conditional on inputs (no set or reset separately) separately) - In systematic systematic relationship relationship to the plant area zones. zones. - Separate set and reset instructions. - Capable of accessing and configuring configurin g redundant CPU / memories in parallel paralle l without causing the equipment to activate and without requiring any override. - Provide I/O monitoring, monitoring, logic modification, relocation relocation of logic bl blocks ocks within memory, search facilities and fault diagnostics. - Use the vendor's vendor's standard configuration system or a language having a one to one correspondence with the logic symbols. - The equipment equipment should should display at least least 25 lines lines of logic. - Use of ladder type presentation presentation should should be avoided, avoided, as these these limit limit the size size of the the gates which can be programmed. - Only the simple simple code statements statements and / or, not inverter inverter and conditional conditional turn on/off on/off of outputs should be used. - The philosophy philosophy behind behind this is to avoid the use of jump jump instructions, separate set and reset instructions for outputs and flags, as these complicate the programs and make errors difficult to find.
11.0
PROJECT REQUIREMEN REQUIREMENTS TS 11.1
FGS Scope of supply and Services FGS scope of supply and services shall be in accordance with the Project specification.
11.2
Project Execution FGS project execution shall shall be in accordance with with the Project Specification. Specification. The FGS scope shall include the supply and testing of serial communication interface interfac e hardware with the PCS. A specific and critical aspect of the scope is that all these links shall be comprehensively tested during the FAT and also at the PCSI location.
11.3
Standardization The system shall be designed to minimize the spare part stock and simplify operator
and maintenance technician training. The same hardware, etc. used to build the IPS system shall also be utilized for the Fire and Fire and Gas System (FGS).
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The FGS shall comprise of standard available hardware, sub assemblies, components, cabinets and racks. 11.4
Description Description and System Sizing Data The scope of FGS hardware is to be determined by the CONTRACTOR during detailed engineering The final system I/O requirement shall be determined from the appropriate project documentation produced produced by CONTRACTOR.
11.5
Consumables and Spare Parts The Contractor shall provide up to the completion of commissioning all consumable items as defined in the project specification.
11.6
Documentation Documentation and data requirements included in the scope of supply for the system include standard documentation documentation and project documentation. documentation. All documentation shall be in the t he English language The FGS documentation documentation required Documentation shall include, but not be limited to, the following:
A functional description of the system Mounting details for each type of detector Index with with tag name, service, detector range and alarm settings Elementary Elementa ry and interconnection interconnect ion diagrams of control panel and system Panel layout drawings Outline dimensions of assembled panel & mounting mounting details Load size calculations calculations Operating and maintenance maintenance manuals Test procedures Software documentation documentation
The Contractor shall include in his tender any restriction relating to the application application of this system for the specific TUV Class requirement. For the purpose of data interchange Oracle and IN Tools application applicat ion packages shall be used . Manuals shall preferably be in electronic format (CD-ROM), with at least one set hardbacked of A4 size, drawing size shall not exceed A3. Prior to FAT testing the vendor shall provide the relevant certificates covering hardware and system software. 11.7
Software and Software Documentation Documentation
11.7.1 General General
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a) a) It is the intent that the system shall utilize standard software to the maximum extent possible. Software implementations implementations of logic requirements shall be developed. Mnemonic and high level language type programming shall not be used. b) Duplicate magnetic media media copies of all system software shall b be e supplied. The supplied software shall be latest implemented and proven release. 11.7.2 Configuration Data and Software Documentation 11.7.2 Documentation a) Software Documentation Documentation shall include include all update update versions of of the system design specifications, including software functional specifications. b) Maximum use shall be made of a system's "self documentation capabilities" in the preparation and submittal of project documents. Contractor shall request vendor to supply examples of these with the quotation and submit these for comments to the Principal. c) Project configuration configura tion data shall preferably be issued and exchanged prior to the SAT using magnetic medium suitable for a personal computer. compute r. However, it shall be mandatory that revised data reissues shall include include a revision revision record as part of the magnetic magnetic medium medium data file. file.
12.0
ENGINEERING AND TRAINING SERVICES All engineering and training services are to be provided in accordance with the Project Specification.
13.0
INSPECTION AND TESTING 13.1
General Requirements Contractor shall be responsible for ensuring directly or indirectly that a fully integrated test of the FGS is performed. performed. This test shall simulta simultaneously neously incorporate incorporate every different component(s) to prove functionality and reliability, simulating site logistics and environmental conditions where possible.
13.2
Manufacturing Manufacturing Test Standard tests on all manufactured and bought out parts and components shall be performed in accordance accordance with ISO 9000. 9000. Tests shall typically typically cover the following following areas: -
Correctness of component component parts
-
Revision level
-
Hardware application
-
Wire-wrap workmanship workmanship (where applicable)
-
Soldering workmanship (where applicable) Marking workmanship
-
Finish workmanship workmanship
All sub-units shall be functionally f unctionally tested in a purpose built test set up, to detect and diagnose hardware and software faults and errors. e rrors. 33 of 36
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13.3
Rev. 4
System Staging All cabinets, components components and sub-assemblies sub-assemblies shall shall be assembled assembled in one area, area, at one time, simulation and loading equipment / devices shall also be connected. Contractor shall maintain a detailed logbook covering the following areas: -
Material deficiencies
-
System activity
-
System problems and resolutions resolutions
-
System testing
System hardware inspection and tests shall include:-
Equipment inventory
-
Visual inspection inspection of all components
-
Continuity check of wiring, and interconnecting interconnecting system cables
-
AC and DC power checks Proper operation of redundant redundant devices
-
Diagnostic checks of all devices
-
Proper operation of communication communication networks
-
Proper operation of serial links
-
Immunity to EMC Earthing system, bonding , etc.
System software tests shall include:-
Run standard diagnostic tests for system functions, security performance etc.
-
Monitor communication errors
-
Loading and verifying all data-bases
System 'burn in' During staging the system is to be continuously energized energized for a period of at least two (2) weeks, 24 hours per day at operating temperat temperature ure and maximum rated load, to burn-in the system and minimize the possibility of process shutdowns caused by infantile failures. Load taking devices devices shall be simulate simulated d at the input /output terminals. The Contractor is to advise the environmental environmental conditions conditions under which the burn-in takes place (i.e. ambient temperature and humidity). A listing of components components which failed during the the burn-in period period shall be available available
during final inspection. inspection. This list should include include the length of time which the faile failed d component was running prior to its failure 13.4
Factory Acceptance Acceptance Test (F.A.T.) The Factory Acceptance Test is intended to verify that the system and its components function properly, that all manufacturing, assembly, software generations and configurations/databases have been implemented correctly correctly and 34 of 36
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completely, and that the system performance is, in all respect, in compliance with the criteria of the agreed agreed procurement procurement specifications. specifications. The test shall cover the following areas:a)
Hardware Overview: The hardware overview will consist of examining all hardware including standard, customized and from sub-vendors, to ensure compliance with the Contractor's specification.
b)
System Integrity The overall system integrity shall be verified verified by failing faili ng the communications paths, cables, and power to verify the proper system operation under each condition.
c)
Foreign Serial Link Interfaces Project equipment, or similar hardware loaded with project configuration together with any simulation, shall be made operable to test and prove that the link operates satisfactorily in terms of transfer of data, synchronization of clocks and performance. 100% operability and functionality of all communication link interfaces shall be included and is a critical project and FAT activity.
d)
Database The following shall be checked and verified:- I/O Configurations Configurations - Logic Configuration Configuration
e)
Logic Function Simulation Tests Tests shall be made by simulating an input and verifying outputs also at the simulator. The FGS shall be tested for:: - 5 point accuracy (0%, 25%, 25%, 50%, 50%, 75%, 75%, 100%) 100%) - Trip point settings - Logic functionality
Output actions - Inhibits - Resets - Scaling Where applicable, the 5 point accuracy test shall generally be applied only once to each sub-system with common analogue to digital and digital to analogue conversion. conversion. A 50% of full scale check will will otherwise suffice. 35 of 36
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f)
13.5
Rev. 4
Non standard standard software shall be checked checked 100%, tests shall shall include reasonable reasonable testing to simulate predictable external component failures to prove functionality when faults exist.
System Integration Testing (SIT) PCS integration integration testing shall shall be carried carried out out at the Process Control System Integrators (PCSI) premises and shall be implemented implemented in accordance accordance with the PCS specification . The PCSI shall co-ordinate co-ordinate the the integration integration test program, supported by the other PCS vendors. The FGS vendor shall supply system dedicated test equipment to perform the PCSI tests. The FGS vendor shall prepare an integrated testing requirements specification for fully testing the FGS with other PCS systems.
13.6
Site Acceptance Test The site acceptance test shall be a duplicate of the tests performed at the Factory Acceptance Test, to confirm correct FGS functionality and operation. The SIT procedure to be developed by the CONTRACTOR and approved by PTTLNG.
14.0
FGS BLOCK DIAGRAM H
H
H
Main network (FTE) Hardwire for trip signals
DCS
SIS
Hardwire I/O signals
Process
FGS (PLC-base (PLC-based) d) MFGCP
Serial link
Hardwire for trip signals Serial link Building #1 LFGCP (Microprocessor based; Fully Addressable system)
Building #2 LFGCP (Microprocessor based; Fully Addressable system)
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