Specification for Fire and Gas Detection System
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PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-06011CS-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. : 7S92-06011CS-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 : The requirement shall be read as a continuation of the Project Specification. Modify : The requirement in the Project Specification shall be replaced by the requirement in this specification. Delete : The requirement in the Project 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 the requirements of this specification does not relieve the Vendor of his responsibility of supply equipment, which is of proper design and construction, fully suited for all specified conditions.
2.2 Article 1.3 System Overview (Modify) All Buildings FGS systems shall be designed per NFPA 72 as well as all applicable Building Codes. Vendor to confirm during detailed design. Vendor’s design shall require PTTLNG/PMC agreement and approval before proceeding. (Modify) The FGS is one of the instrument systems which form part of the overall Integrated Control System (ICS). Testing of all interfaces between FGS and other parts of ICS is detailed in specification 7S92-06011-CS-TS-003 "Specification for Process Control System ". This specification defines also the boundary for the FAT and SIT.
PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-06011CS-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 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 (Modify) FIT
Factory Integration Test (carried out by PCSI (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-CS-TS-001, Instrument Design 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 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. : 7S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 5 of 8
(Modify) b) FGS cabinets shall be fed from redundant 230 VAC – UPS instrument distribution boards.
1
2.8 Article 5.3 Earthing System (Modify) 5.3.2 For cabling and Earthing concepts, refer to 7S92-06011-CS-TS-001 “Instrument Design Criteria”.
2.9 Article 5.6 Time Synchronization (Modify) The FGS shall be synchronized with the plant master clock system (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 “Specification for Control Panels”.
2.12 Article 6.8 Cabinet Mounted Panels (Modify) Vendor 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. : 7S92-06011CS-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) : 7S92-06011-PC-DS-205 Piping and Instrument 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 in the Project Specification, Annex J, section 12.
2.15 Article 7.3 CCR FGS Control Panels (Modify) 7.3.1 A FGS 52” touch screen LCD monitor Mimic Panel shall also be provided in the Fire Station Building, this facility will be for "Read Only" purposes.
1
2.16 Article 8.1 General (Modify) The provisional quantities and location of detectors are shown on Fire and Gas Detection Plan drawings 7S92-A1-06011-1300-CS-360.
2.17 Article 8.4 Smoke Detectors (Modify) 8.4.2 Smoke detectors shall be either fixed head or reflection type. Smoke detectors shall not be provided for indoor cable trays. 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 ensure that all interfaces between the FGS and following equipment are correctly engineered.
PMC
Specification for
Fire & Gas Detection System
Doc. No. : 7S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 7 of 8
2.19 Article 11.5 Consumables and Spare Parts (Modify) The Vendor shall provide up to the completion of commissioning all consumable items as defined in the project specification.
2.20 Article 11.6 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 (Modify) Vendor 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 component (s) to prove functionality and reliability, simulating site logistics and environmental conditions where possible.
2.22 Article 13.3 System Staging (Modify) Vendor shall maintain a detailed logbook covering the following areas: - Material deficiencies - System activity - System problems and resolutions - System testing (Modify) Load taking devices shall be simulated at the input /output terminals. The Vendor is to advise the environmental conditions under which the burn-in takes place (i.e. ambient temperature and humidity).
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. : 7S92-06011CS-TS-014 Rev. :1 Date : 22 Jul. 2008 Page : 8 of 8
Fire & Gas Detection System (FGS)
3. Attachment
7S92-A3-06011-1300-CS-023, Rev. 0, System Block Diagram for Fire & Gas Detection System (FGS) 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 VM Contractor Description By
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........................................................................................................... 1 1.1 1.2 1.3
General...........................................................................................................1 Objectives.......................................................................................................2 System Overview............................................................................................2
2.0 CODES AND STANDARDS .......................................................................... 3 2.1 2.2 2.3
Project Specifications and Drawings ...............................................................3 Local Codes and Standards............................................................................4 International Standards...................................................................................4
3.0 ABBREVIATIONS.......................................................................................... 4 4.0 CLIMATIC AND SITE DATA ......................................................................... 5 4.1 4.2
Equipment location .........................................................................................5 Area Classification ..........................................................................................5
5.0 GENERAL REQUIREMENTS........................................................................ 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7
Equipment Locations and Design Criteria .......................................................5 Reliability and Redundancy.............................................................................6 Electrical Requirements ..................................................................................6 System Spareage and Loading Criteria...........................................................7 Standard Hardware and Software ...................................................................7 Time Synchronization .....................................................................................7 FGS Graphics Specification ............................................................................7
6.0 HARDWARE REQUIREMENTS .................................................................... 8 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12
General...........................................................................................................8 Main Fire and Gas Control Panel ....................................................................8 SER Hardware................................................................................................9 PLC System..................................................................................................10 Engineering Workstation ...............................................................................11 MIMIC Panel.................................................................................................11 Main Distribution Frame (MDF) Cabinets ......................................................11 Cabinet Mounted Panels...............................................................................12 Input / Outputs Structure ...............................................................................12 Local Fire & Gas Control Panel.....................................................................15 Earth Leakage Detection...............................................................................16 System Segregation......................................................................................17
7.0 FUNCTIONAL REQUIREMENTS ................................................................ 17 7.1 7.2
General.........................................................................................................17 Overview.......................................................................................................17 i
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 (HMI) ..................................................................19 Serial Communications .................................................................................21 Interfaces with Other ICS Systems ...............................................................21 Compliance...................................................................................................22 Diagnostics ...................................................................................................23
8.0 DETECTION SYSTEMS .............................................................................. 23 8.1 8.2 8.3 8.4 8.5 8.6 8.7
General.........................................................................................................23 Flammable Gas Detection.............................................................................23 Fire Detection ...............................................................................................25 Buildings .......................................................................................................26 LNG Leakage Detection................................................................................27 Toxic Gas Detection......................................................................................28 Detectors Voting ...........................................................................................28
9.0 ACTIVATION SYSTEMS ............................................................................. 28 9.1 9.2 9.3
General.........................................................................................................28 Water Spray / Deluge / Foam Systems .........................................................28 Audible Alarm and Beacon Systems .............................................................29
10.0 CONFIGURATION AND PROGRAMMING EQUIPMENT ........................... 30 10.1 General.........................................................................................................30 10.2 Editing...........................................................................................................30 10.3 Configuration ................................................................................................31
11.0 PROJECT REQUIREMENTS ...................................................................... 31 11.1 11.2 11.3 11.4 11.5 11.6 11.7
FGS Scope of supply and Services...............................................................31 Project Execution..........................................................................................31 Standardization.............................................................................................31 Description and System Sizing Data .............................................................32 Consumables and Spare Parts .....................................................................32 Documentation..............................................................................................32 Software and Software Documentation .........................................................32
12.0 ENGINEERING AND TRAINING SERVICES .............................................. 33 13.0 INSPECTION AND TESTING ...................................................................... 33 13.1 13.2 13.3 13.4 13.5 13.6
General Requirements..................................................................................33 Manufacturing Test .......................................................................................33 System Staging.............................................................................................34 Factory Acceptance Test (F.A.T.) .................................................................34 System Integration Testing (SIT)...................................................................36 Site Acceptance Test ....................................................................................36
14.0 FGS BLOCK DIAGRAM .............................................................................. 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 as the TERMINAL). The Fire & Gas Control System (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” 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 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 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 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 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 Panel (LFGCP) – Addressable, Microprocessor Based
The Building FGS system shall be a complete addressable fire and gas detection System.
1.2
1.1.2
FGS equipment for the Jetty Area and Truck Loading shall be integrated with the main FGS via remote I/O.
1.1.3
Deleted
Objectives 1.2.1
The principal objectives of the Fire and Gas 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.
-
Detecting incipient fire and the presence of fire.
-
Providing automatic and / or facilities for manual activation of the fire protection system, as required.
-
Initiating signals, both audible and visible, as required, warning of the detected hazards.
1.3
Provide sequence of event recording for analysis purposes
System Overview All Fire and Gas safety critical functions shall be implemented with independent instrumentation and shall be 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 (FAR's), Auxiliary Instrument Rooms (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 switch panel. The control panels shall be integrated 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 control panels (VDU / printer) for display, recording and transmission of receipt of the status of fire and gas devices.
the CCR FGS mimic panel for display of the status of fire and gas devices throughout the TERMINAL.
the CCR FGS control panels (hard wired switches) for safety critical functions.
other sub-system FGS PLC's for the initiation of alarm and protection systems etc.
All Buildings FGS systems shall be designed per NFPA 72 as well as all applicable Building Codes. CONTRACTOR to confirm during detailed design. CONTRACTOR’s design shall require PTTLNG/PMC agreement and approval before proceeding. For main alarm overview and hardware layouts, the LNG complex shall be split into geographical areas. These 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 instrumentation 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). Testing of all interfaces between FGS and other parts of ICS is detailed in specification A3CA-06011-270-70005 "Specification for Process Control System ". This specification defines also the boundary for the FAT and SIT.
2.0
CODES AND STANDARDS The equipment shall comply with the latest issue of the following documents:2.1
Project 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 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 Codes and Standards
2.3
International Standards National Fire Protection Agency (NFPA) NFPA 59A (2006): NFPA 70: NFPA 72: NFPA 496:
Standard for the Production, Storage, and Handling of Liquefied Natural Gas (LNG) National Electric Codes 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): Installation and Equipment for Liquefied Natural Gas – Design of Onshore Installations
3.0
BS 5445
Specification of components of systems (Parts 1 - 2 - 7 - 8).
automatic fire
BS 5839
Fire Detection and Alarm Systems in Buildings
BS 6020
Instrumentation for the detection of 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 Instrument Room Central Control Room Closed Circuit Television Central Processing Unit Distributed Control System Emergency Depressurizing Engineering Procurement Construction Commissioning Contractor Electro Magnetic Compatibility Emergency Shutdown Factory Acceptance Test Field Auxiliary Room Factory 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 4 of 36
detection
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 RDAS SAT SER SIS SIT SIGTTO SOV TCS TSO UPS VDU
4.0
Rev. 4
Lower Explosive Limit Manual Call Point Main Control Room Main Distributed Frame Maintenance Override Switch Maintenance Override Enable Switch National Fire Protection Association Process Control System Process Control System Integrator Programmable Logic Controller Rotating Equipment Data Acquisition System Site Acceptance Test Sequence of Events Recorder Safety Instrumented System System 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. 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 All instrumentation shall be designed and installed in compliance with area classification. For reference see area electrical classification 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 environmental conditions. Contractor shall confirm whether special conditions are 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 availability, reliability 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 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 high availability. These requirements lead to redundancy of system hardware. Details for PLCs are described in paragraph 6.0.
5.3
Electrical Requirements 5.3.1
Power Supplies c) Power supplies shall be provided in accordance with specification A3CA06011-270-70006 and d) FGS cabinets shall be fed from dual 230 VAC – UPS instrument distribution boards. e) Separate sets of redundant power supplies are required for: - System related hardware - Field related hardware f) Status indication and fault alarm of all power supply modules inside the cabinets shall be provided.
5.3.2
Earthing System For cabling and Earthing concepts refer to A3CA-06011-270-70001 “Instrument Design Criteria”.
5.3.3
The Contractor shall ensure that the earthing is in full compliance with the ICS Vendor specific earthing requirements.
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Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
5.4
Rev. 4
System Spareage and Loading Criteria 5.4.1
Spareage Requirements Spare = Installed I/O - Used I/O * 100 % Used I/O Spare hardware and space shall be included as follows:a) Minimum 20 % fully connected and functional spare I/O shall be available following plant commissioning. This spareage shall be evenly distributed throughout the system. b) Multi-pair cables terminating in MDF cabinets shall include at least 20 % unused pairs which shall be connected in sequence to spare terminals along with used pairs. The Multipair spares shall be available post plant commissioning c) Additionally, systems shall include wired rack / slots to enable system I/O to be increased by 20 % after plant commissioning (cards shall not be installed). It shall be possible to add such hardware without shutting down the system and without causing process upset.
5.4.2
Loading Criteria a) After plant commissioning, microprocessor based system capacity, RAM and communications bus loading shall not exceed 70 %, of the maximum capability. b) Power supply units shall be sized such that they are only loaded to 50 % of their capacity (inclusive projected 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 stamping is not compromised. The necessary interfaces to the master clock system shall be provided.
5.7
FGS Graphics Specification The FGS graphic specification shall be developed by CONTRACTOR during detailed design and shall follow the PCS graphic specification. The number of pages should cover the whole plant area (ie. example, process, utilities, building, truck loading, jetty area, etc). Moreover, PTTLNG/PMC shall agree and approve before proceeding.
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Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
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 MFGCP consisting of graphics display, networking communication system. Each building or occupied shelter shall include a dedicated addressable microprocessor based LFGCP complete with local audible notification system. The MFGCP shall communicate with the plant emergency evacuation 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 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 systems shall be allowed 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 FGS sub-system shall communicate via serial communication by means of a dedicated fail safe, self checking and fully redundant 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 annunciate all faults at PLC card level. All FGS detectors shall be 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 of FGS detectors i.e. continuous line monitoring. Where required interface modules shall be used between field instrumentation and PLC I/O (e.g. Isolation barriers and signal conditioning 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 and fire protection 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 at the MFGCP and in the PCS Historian database. The MFGCP shall also detect all changes in status of monitored points, provide event 8 of 36
Jetty Development and LNG Receiving Terminal Project Specification for Fire & Gas Detection System Doc. No. A3CA-06011-FP-002
Rev. 4
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 be transmitted based on the location of the 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) 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 fire protection systems (as applicable). 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 phase. The FGS system shall provide the following response capabilities:
6.3
Fire and gas control panel indication
Subsequent fire alarm conditions to include at least 5 previous events starting in order with the highest priority.
Inert gas extinguishing system activation
Water spray system activation from pressure switches
Shutdown and/or re-circulate HVAC and electrical power (except for life safety purposes)
Activation of PA/GA Tone Generator and strobes units in local buildings
Activation of plant emergency communication system and activation of sirens, and PA/GA and strobes, site-wide.
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 paths/busses External 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 run 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 under program control. The timers shall be 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 be provided with 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 engineer. The messages shall contain sufficient information for defective card replacement. Apart from the message display, full diagnostics shall be accessible through the screen of the engineering workstation. Input / output status shall also be available on the engineering workstation. Live update of the functional logic diagrams shall assist in system troubleshooting. An overview of system failure messages and diagnostics is required.
6.4.6
System 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 in the CCR AIR shall contain a HMI for engineering and maintenance. A desktop PC engineering workstation shall be provided in the CCR. The engineering work station shall have access to the complete FGS system.
6.5.2
FGS System shall be capable of communicating with the PC workstations for performing the following functions: - On-line & Off-line 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. 6.6
MIMIC Panel 6.6.1
6.7
The Mimic Panel in the CCR for the FGS system shall be a 52” 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 as on the VDU operator station. 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 interface components such as: Power Supplies
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6.8
-
Isolator amplifiers
-
Proximity amplifiers Detector Interface modules Terminals Cable - and wire supports
Rev. 4
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.
6.8.2
Deluge, Foam and Siren Activation Activation of fire fighting 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 for plant located beacons and audible alarms. The panel shall be designed such that its layout is representative of the FGS area zones. Deluge and foam activation switches shall require double 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 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 24 V(dc) floating power supply should be galvanically separated from the logic components. A FGS loop shall always be powered from 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 I/O 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 safety integrity of the plant. Signals to / from the system shall either be via redundant fail safe serial data links or hardwired. Typical safety critical signals are: - Deluge and Horn manual initiators.
b)
-
Detectors and SOV in and output signals. Trip initiating signals from other ICS equipment . Machinery protection FGS related-signals.
-
Plant visual and audible alarm initiators.
-
Maintenance Override (MOS) enable inputs.
Non critical signals to / from the system may either be via serial data links or hardwired. Non safety critical signals i.e.: alarms, indication, sequence of events (SER), reset switches and maintenance override switches shall comply with the following: -
Hardwired non safety critical circuits shall be 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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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 from each signal in the redundant 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. In the event of an input card or processor failure, the remaining correct analogue input shall be used for safeguarding logic functions and transmission to the PCS. Input module requirements 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 for logic processing shall be transmitted to the PCS via serial communication. 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
Rev. 4
Output Modules Output card design criteria :- LED indicating output energized. -
Selectable to act as passive or active power source
-
Floating from earth. Open circuit detection
-
Potential free contacts, rated 24 VDC, 1 A. (goldplated or 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 resistance”. The I/O shall be the 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 The LFGCP shall accept, process and evaluate the following types of signals:
Addressable analog smoke detectors (buildings)
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Addressable heat detectors (buildings) Addressable manual fire alarm stations (MAC) in buildings
Inert gas extinguishing system pressure operated switch contact (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
Excessive electrical "noise" on the signaling line circuit
Ability to identify the location of short and open circuit conditions
Ability to identify the location of 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 isolation by a single point or group of points. The system shall ignore signals from input devices when isolated. The system shall annunciate and remain in a trouble state while any fire alarm device is isolated. The system shall provide identification of point type, location and status. Each addressable and analog fire alarm device shall have a field assigned unique minimum 32 character device location message. The system shall provide addressable 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 detection shall be provided. It shall consist of a detection/alarm system, which continuously monitors and alarms if one of the connected circuits has an earth fault.
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This feature shall be implemented for each field power supply feeder to a single field circuit. Upon earth fault detection a local lamp shall illuminate inside the MDF cabinet and a common alarm shall be transmitted to the PCS. An important purpose of the earth leakage detection system is to identify 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. Signals shall be distributed throughout 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 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 in the Project Specification, Annex J, section 12.
The FGS shall be operational at all times, even during total plant 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 subsystem to another, they shall be hardwired or routed over the FGS System Bus and not routed via PCS communication 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 locations throughout 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 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) 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 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. In line with the functional structure, the following types of alarms shall be presented: High level (LEL) flammable gas High High level (LEL) flammable 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 system shall be developed which achieves the following objectives: Minimize the number of active alarms Maximize the information contained in the alarms Obtain effective presentation of alarms All new buildings e.g. Service building, Warehouse, AHs, FARs, Substations, etc. shall have indoor detectors and fire panels. 7.3
Human Machine Interface (HMI) 7.3.1
CCR FGS Control Panels The HMI comprises of VDU graphic displays and hard wired switch panels. The HMI shall be the primary interface for all FGS related 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 from the control panels. The VDU graphic layout 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 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 FGS shall be a dedicated set, serving only the FGS monitoring, status and control. The operation for PCS control on this panel is 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 the other monitor shall be used as a MIMIC for the FGS for this project (these two monitors will share the same processing unit). 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. In general, the MOS shall be configured to prohibit the activation of Fire Sirens / Beacons / Sounders and the Fire water pump(s), however alarms of circuits under MOS condition shall generate alarms in the CCR. To apply a MOS function the following two steps are required:: - Step one the Maintenance Override Enable Switch (MOES) is activated. (see for details a) below) - Step two the 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 regardless the status of the PCS or communication link. The "MOES and 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
- Flashing
(process condition is healthy). 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 per Process Unit Area zone. c) MOS activation The PCS sends a "MOS request” via the serial link to the IPS. The IPS determines if the use of the MOS is permitted. This is only permitted if the "MOES” is in the enable position and only one MOS is selected for a particular Process Unit Area zone. If both 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", 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 via the PCS screen. The tag will change color from blinking red to black. 7.4
Serial Communications Only standard international communication protocols shall be utilized. (Such as EIA RS-232-c, modbus RTU, RS-484, Ethernet 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 different systems. Special attention shall 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 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 above, other 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 provide selected inputs for 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 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 interfaced with 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 alarm (flammable and / or toxic) - Common Fire detection alarm - Common Heat detection alarm - Protection system activated (gaseous, deluge etc.) - System fault - Maintenance override selected / 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 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 Compressor 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 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. 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. The detectors shall be suitable for location in hazardous areas. The sensors shall be built into an explosion-proof, stainless steel housing. All fire and gas detectors for use in process areas shall be certified as a minimum for use in zone 1 areas. All detectors shall be installed with fire 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 and IR open path detector. Only IR gas 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 infrared energy at certain 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 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 from the transmitter to the 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 can be projected over 30 to 90 m long. The open path IR gas detectors provide information about the average flammable 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 detectors shall 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 air gases. The detectors shall be mounted below or above the possible sources accordingly. Collecting cones may be considered when appropriate. Point IR gas detectors shall be installed near the seals of gas compressors 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. 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 system. Alarms shall be implemented as 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 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 flammable gas above the 'H' alarm 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 be typically located in the air inlet of: Electrical substations located within the plant area. Field auxiliary rooms (FAR). Analyzer houses. Air compressors. Air intakes of building(s) HVAC 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. Detectors shall be mounted close 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 two detectors reach 20% LEL, an alarm will be activated; the fresh air intakes will be closed and the ventilation fans 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 if remedial actions are to be effective. Two principal forms of fire detection shall be employed: Human (Manual Call Point) Automatic fire detection.
8.3.2
Manual Call Points (MCPs) Manual call points shall be used to communicate fire detection to the CCR. Manual Alarm Call Points (Alarm Stations) shall be provided as a minimum based on the following criteria:
Along roads in the plant area at interval not exceeding 100 m Along roads in storage tank area not exceeding 200 m Near or at location having a high risk such as process equipment, valve manifold, jetty head Inside buildings, office entrance, canteen, warehouse, medical, guard house, etc.
In general, the Alarm Call Points are provided at the building exits to enable operators to raise an alarm in an emergency. Manual Alarm Call Points shall be mounted at a height of 1.2 m above floor or grade 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 shall be achieved by the following types 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 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 generator room. These detectors are designed to activate at both a fixed temperature and fast thermal rate of rise due to fire growth.
8.4
Buildings 8.4.1
General All building related fire and safety facilities 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 develop 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 shall be either fixed head or reflection type. Smoke detectors shall not be provided for indoor cable trays. The Contractor 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 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 spaces. This type of detector detects incipient smoke particles formed by overheated cable installations. The typical construction of such an installation employs a detector cabinet containing detectors connected to sample points via sample lines. The aspirator sampling system is connected to the 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 computer rooms, computer auxiliary rooms. Inside instrument auxiliary rooms, cabinets, floor cavity and cable routes.
When smoke is detected, an alarm shall be triggered locally and in the CCR. 8.5
LNG Leakage 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 potential 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 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.
8.6.1
Oxygen Deletion Oxygen depletion detection shall be provided in enclosed rooms where nitrogen is used, such as analyzer building. The detector shall be 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. 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 means a minimum three detectors in each fire detection zone and a confirmed fire or gas leak is based on 2 or more detection. 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. Detection voting will be used for this project. For process area 2ooN shall be employed, while in non-process area including air intake, 1ooN shall be used. 1ooN voting logic shall also be used for 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 foam system. Such systems are activated via FGS, following signals received from the detection systems. Details of the fire protection 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 opening of the deluge valve will allow water to flow into the system piping and to discharge from the water spray 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 System. All spray / 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 systems shall be available 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 from a LNG spill. High Expansion Foam Concentrate shall be stored in the Foam Bladder Tank. The foam concentrate is 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 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 of the foam systems shall be available for display 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 via motor driven sirens for 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 of at least 110 dB(A) at 1 meter In order to obtain one plant identical alarm system the duration of the alarm signal shall be controlled via the FGS Plant Alarm & Warning System. The alarm duration shall be adjustable between 1 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 phase, having a mark space ratio of 1 :1, cycle 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 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 silence 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 time delay. 29 of 36
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Flammable gas beacons shall be of strobe type and colored blue. The "all clear" gas alarm shall be a continuous tone of not less than 2 minute duration at a frequency of 2000 Hz . The timing is set via 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 shall annunciate by an interrupted tone having a mark space ratio of 1:1, cycle time: 2 seconds, frequency 1000 Hz, with a sound level of at least 105 dB(A) at 1 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 production a software development package shall be provided. Configuration equipment shall be:
10.2
-
Capable of being plugged in, or removed from the CPU's whilst they are operation, without 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. 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 should be organized as follow:- Outputs are always conditional on inputs (no set or reset separately) - In systematic relationship to the plant area zones. - Separate set and reset instructions. - Capable of accessing and configuring redundant CPU / memories in parallel without causing the equipment to activate and without requiring any override. - Provide I/O monitoring, logic modification, relocation of logic blocks within memory, search facilities and fault diagnostics. - Use the vendor's standard configuration system or a language having a one to one correspondence with the logic symbols. - The equipment should display at least 25 lines of logic. - Use of ladder type presentation should be avoided, as these limit the size of the gates which can be programmed. - Only the simple code statements and / or, not inverter and conditional turn on/off of outputs should be used. - The philosophy behind this is to avoid the use of 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 REQUIREMENTS 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 be in accordance with the Project Specification. The FGS scope shall include the supply and testing of serial communication interface 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 Gas System (FGS).
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The FGS shall comprise of standard available hardware, sub assemblies, components, cabinets and racks. 11.4
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 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 and project documentation. All documentation shall be in the English language The FGS 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 tag name, service, detector range and alarm settings Elementary and interconnection diagrams of control panel and system Panel layout drawings Outline dimensions of assembled panel & mounting details Load size calculations Operating and maintenance manuals Test procedures Software documentation
The Contractor shall include in his tender any restriction relating to the application of this system for the specific TUV Class requirement. For the purpose of data interchange Oracle and IN Tools application 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 11.7.1 General
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a) It is the intent that the system shall utilize standard software to the maximum extent possible. Software implementations of logic requirements shall be developed. Mnemonic and high level language type programming shall not be used. b) Duplicate magnetic media copies of all system software shall be supplied. The supplied software shall be latest implemented and proven release. 11.7.2 Configuration Data and Software Documentation a) Software Documentation shall include all update versions 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 data shall preferably be issued and exchanged prior to the SAT using magnetic medium suitable for a personal computer. However, it shall be mandatory that revised data reissues shall include a revision record as part of the magnetic medium data 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. This test shall simultaneously incorporate every different component(s) to prove functionality and reliability, simulating site logistics and environmental conditions where possible.
13.2
Manufacturing Test Standard tests on all manufactured and bought out parts and components shall be performed in accordance with ISO 9000. Tests shall typically cover the following areas: -
Correctness of component parts Revision level
-
Hardware application Wire-wrap workmanship (where applicable)
-
Soldering workmanship (where applicable) Marking workmanship
-
Finish workmanship
All sub-units shall be functionally tested in a purpose built test set up, to detect and diagnose hardware and software faults and errors. 33 of 36
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13.3
Rev. 4
System Staging All cabinets, components and sub-assemblies shall be assembled in one 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 System testing
System hardware inspection and tests shall include:Equipment inventory -
Visual inspection of all components Continuity check of wiring, and interconnecting system cables
-
AC and DC power checks Proper operation of redundant devices Diagnostic checks of all devices Proper operation of 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 for a period of at least two (2) weeks, 24 hours per day at operating temperature and maximum rated load, to burn-in the system and minimize the possibility of process shutdowns caused by infantile failures. Load taking devices shall be simulated at the input /output terminals. The Contractor is to advise the environmental conditions under which the burn-in takes place (i.e. ambient temperature and humidity). A listing of components which failed during the burn-in period shall be available during final inspection. This list should include the length of time which the failed component was running prior to its failure 13.4
Factory 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 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 procurement 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 by failing 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 - Logic 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%, 50%, 75%, 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. A 50% of full scale check will otherwise suffice. 35 of 36
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f)
13.5
Rev. 4
Non standard software shall be checked 100%, tests shall include reasonable testing to simulate predictable external component failures to prove functionality when faults exist.
System Integration Testing (SIT) PCS integration testing shall be carried out at the Process Control System Integrators (PCSI) premises and shall be implemented in accordance with the PCS specification . The PCSI shall co-ordinate the 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 MI
H MI
H MI Main network (FTE) Hardwire for trip signals
DCS
SIS
Hardwire I/O signals
FGS (PLC-based) MFGCP
Serial link
Hardwire for trip signals Serial link
Process area
Building #2 LFGCP (Microprocessor based; Fully Addressable system)
Building #1 LFGCP (Microprocessor based; Fully Addressable system)
Note: Each building (LFGCP) will connect directly to MFGCP in CCR.
Simplified diagram to show the interface between MFGCP and LFGCP
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