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
Fire & Gas Detection System
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 Issued to EPC Contractor
VM GH GH
Rev Date Description By Checked Approved Acknw’ed by PTT
Table of Contents
Page
1.0 SCOPE... 1
1.1 General...1
1.2 Objectives...2
1.3 System Overview...2
2.0 CODES AND STANDARDS ... 3
2.1 Project Specifications and Drawings ...3
2.2 Local Codes and Standards...4
2.3 International Standards...4
3.0 ABBREVIATIONS... 4
4.0 CLIMATIC AND SITE DATA ... 5
4.1 Equipment location ...5
4.2 Area Classification ...5
5.0 GENERAL REQUIREMENTS ... 5
5.1 Equipment Locations and Design Criteria ...5
5.2 Reliability and Redundancy...6
5.3 Electrical Requirements ...6
5.4 System Spareage and Loading Criteria...7
5.5 Standard Hardware and Software ...7
5.6 Time Synchronization ...7
5.7 FGS Graphics Specification ...7
6.0 HARDWARE REQUIREMENTS ... 8
6.1 General...8
6.2 Main Fire and Gas Control Panel ...8
6.3 SER Hardware...9
6.4 PLC System...10
6.5 Engineering Workstation ...11
6.6 MIMIC Panel...11
6.7 Main Distribution Frame (MDF) Cabinets ...11
6.8 Cabinet Mounted Panels...12
6.9 Input / Outputs Structure ...12
6.10 Local Fire & Gas Control Panel...15
6.11 Earth Leakage Detection...16
6.12 System Segregation...17
7.0 FUNCTIONAL REQUIREMENTS ... 17
7.1 General...17
7.2 Overview...17
ii
7.3 Human Machine Interface (HMI) ...19
7.4 Serial Communications ...21
7.5 Interfaces with Other ICS Systems ...21
7.6 Compliance...22
7.7 Diagnostics ...23
8.0 DETECTION SYSTEMS ... 23
8.1 General...23
8.2 Flammable Gas Detection...23
8.3 Fire Detection ...25
8.4 Buildings ...26
8.5 LNG Leakage Detection...27
8.6 Toxic Gas Detection...28
8.7 Detectors Voting ...28
9.0 ACTIVATION SYSTEMS ... 28
9.1 General...28
9.2 Water Spray / Deluge / Foam Systems ...28
9.3 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 FGS Scope of supply and Services...31
11.2 Project Execution...31
11.3 Standardization...31
11.4 Description and System Sizing Data ...32
11.5 Consumables and Spare Parts ...32
11.6 Documentation...32
11.7 Software and Software Documentation ...32
12.0 ENGINEERING AND TRAINING SERVICES ... 33
13.0 INSPECTION AND TESTING ... 33
13.1 General Requirements...33
13.2 Manufacturing Test ...33
13.3 System Staging...34
13.4 Factory Acceptance Test (F.A.T.) ...34
13.5 System Integration Testing (SIT)...36
13.6 Site Acceptance Test ...36
14.0 FGS BLOCK DIAGRAM ... 36
1.0 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)
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- 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.
1.1.2 FGS equipment for the Jetty Area and Truck Loading shall be integrated with the main FGS via remote I/O.
1.1.3 Deleted 1.2 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.
- Provide sequence of event recording for analysis purposes 1.3 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:
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
A3CA-06011-270-70004 Process Control and Safety Instrumented Systems Philosophy A3CA-06011-270-70005 Specification for Process Control
System
A3CA-06011-270-70006 Specification for Safety Instrumented Systems
A3CA-06011-1000-FPR-001 Fire Protection Philosophy ( Design Criteria)
A3CA-A1-06011-0300-EL-001 Area Classification Drawings, Electrical
4 of 36 2.2 Local Codes and Standards
Applicable Thai Codes and Standards 2.3 International Standards
National Fire Protection Agency (NFPA)
NFPA 59A (2006): Standard for the Production, Storage, and Handling of Liquefied Natural Gas (LNG)
NFPA 70: National Electric Codes NFPA 72: National Fire Alarm Code
NFPA 496: 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
BS 5445 Specification of components of automatic fire detection systems (Parts 1 - 2 - 7 - 8).
BS 5839 Fire Detection and Alarm Systems in Buildings
BS 6020 Instrumentation for the detection of combustible gases.
3.0 ABBREVIATIONS
AIR Auxiliary Instrument Room
CCR Central Control Room
CCTV Closed Circuit Television CPU Central Processing Unit DCS Distributed Control System
EDP Emergency Depressurizing
EPCC Engineering Procurement Construction Commissioning Contractor EMC Electro Magnetic Compatibility
ESD Emergency Shutdown
FAT Factory Acceptance Test
FAR Field Auxiliary Room
FIT Factory Integration Test (carried out by PCSI) FGCP Fire and Gas Control Panel
FGS Fire and Gas System
HMI Human Machine Interface
ICS Integrated Control and Safety System IPF Instrumented Protective Function IPS Instrumented Protective System
I/O Input/Output
IS Intrinsically Safe LAN Local Area Network LED Light Emitting Diode
LEL Lower Explosive Limit
MCP Manual Call Point
MCR Main Control Room
MDF Main Distributed Frame MOS Maintenance Override Switch
MOES Maintenance Override Enable Switch NFPA National Fire Protection Association
PCS Process Control System
PCSI Process Control System Integrator PLC Programmable Logic Controller
RDAS Rotating Equipment Data Acquisition System
SAT Site Acceptance Test
SER Sequence of Events Recorder SIS Safety Instrumented System
SIT System Integration Test (carried out by PCSI)
SIGTTO Society of International Gas Tanker and Terminal Operators
SOV Solenoid Operated Valve
TCS Terminal Control System
TSO Tight Shut Off
UPS Un-Interruptible Power Supply VDU Visual Display Unit
4.0 CLIMATIC AND SITE DATA
4.1 Equipment locationThe 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. The Contractor shall confirm whether special conditions are required.
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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The following locations will contain AIRs for the installation of FGS equipment PLC cabinets:
- Jetty Substation - Truck Loading CR - CCR – AIR
5.2 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.
- Mean Time Between Failures (MTBF) - > 80,000 hours - Mean Time to Repair 4 hrs. (Max)
- Availability - > 99.99 % 5.2.2 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 A3CA-06011-270-70006 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.
5.4 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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6.0 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
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:
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 gasextinguishing 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.
6.3 SER Hardware
All necessary SER hardware and software shall be designed and integrated in the FGS.
10 of 36 6.4 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
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