Job Specification For Fire and Gas Sys

Shazand Arak Refinery Expansion and
Upgrading Project
Job Specification
For
Fire and Gas System
Originator Project No. :
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Page 1 of 42
File Ref. : T:\Issued Documents to Employer\Engineering Directorate\FA\SP-2260-90421-3\SP-2260-90-421-3.doc
Job Specification
For
Fire and Gas System
03
Revised as Indicated as per NIOEC Comments
14-Mar-2009
R.Khalili
02
24-Aug-2008
01
15-Jan-2008
00
Issued for Approval
Rev.
Description
K.Faraji
B.Amirani
R.Khalili
K.Faraji
B.Amirani
R.Khalili
K.Faraji
B.Amirani
05-Jul-2007
R.Khalili
K.Faraji
B.Amirani
Date
Prepared
8350-U00-FAS-SPC-0012
Checked
POD:
EX
This Document belongs to NIOEC and is confidential.

Shazand Arak Refinery Expansion And Upgrading Project ,Islamic Republic of Iran.
Approved
POI:
IFD
Status:
AC
IFA

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 2 of 42
Table of Contents
1.
Purpose ......................................................................................................................4
1.1
1.2
1.3
1.4
1.5
1.6
2.
Applicable Documents................................................................................................5
2.1
Codes and Standards ................................................................................................... 5
3.
Definitions and Abbreviations .....................................................................................7
4.
Overview.....................................................................................................................8
5.
General Requirements ...............................................................................................8

5.1
5.2
5.3
5.4
5.5
5.6
6.
Scope ........................................................................................................................... 4
Conflicts ........................................................................................................................ 4
Deviations ..................................................................................................................... 4
Equivalent Materials ..................................................................................................... 4
Vendor Responsibilities ................................................................................................ 4
Language and Units ..................................................................................................... 5
Environmental Conditions ............................................................................................. 8

Hazardous Area Classification and Ingress Protection................................................. 8
Electrical Power ............................................................................................................ 8
Cable Specification ....................................................................................................... 9
Noise Immunity (RFI/EMI) .......................................................................................... 10
Reliability of Fire & Gas System ................................................................................. 10
Design Philosophy....................................................................................................12
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
General ....................................................................................................................... 12
System Architecture ................................................................................................... 12
FGS Panels Configuration .......................................................................................... 14
System CPU ............................................................................................................... 14
Input/Output Modules ................................................................................................. 15
Communication Interface ............................................................................................ 16
Operator Interfaces ..................................................................................................... 17
FGS Monitoring & Control System Software .............................................................. 18
System Cabinets ........................................................................................................ 20
FGS Devices .............................................................................................................. 23
FGS Field Devices ...................................................................................................... 24
FGS Devices inside the Building ................................................................................ 28
FGS Connection with Other Systems ......................................................................... 31
7.
FGS Design, Engineering & Procurement ...............................................................34
8.
Inspections and Tests ..............................................................................................35

8.1
9.
Tests ........................................................................................................................... 35
Training.....................................................................................................................38
10.
Planning & Time Schedule ...................................................................................38
11.
Deviations & Alterations........................................................................................39
12.
Documentation ......................................................................................................40
12.1
Supply of documents .................................................................................................. 40


Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 3 of 42
Exclusion...............................................................................................................41
14.
Spare Parts ...........................................................................................................41
15.
Special Tools ........................................................................................................42
13.


Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 4 of 42
1. Purpose
1.1
Scope
This specification is intended to establish the minimum requirements to be followed for
the design, manufacturing and testing of Fire & Gas Alarm System to be supplied for
Shazand Arak Refinery and Product Upgrading Project in fully integrated and functional
state.
Although this project is the expansion project to be constructed in the existing Arak
Refinery, the new system should be designed and installed for the new facilities
independently from that for the existing system.
This specification is not applicable for the quantity of operator and engineering
workstations. The quantities for the whole plant will be finalized later.
All components and accessories furnished with system shall be manufactures highest
standard and shall be designed and fabricated in accordance with all applicable codes
and standards; which shall be reviewed for acceptance by the client.
The FGS shall be a field proven type and shall have at least three (3) years of operation
history in similar plants with full satisfaction of the users.
1.2
Conflicts
In case of any conflicts among the mentioned reference codes and standards in section
2 and this specification, Vendor shall notify the purchaser. Also the Vendor shall call any
above mentioned conflicts to the attention of the Purchaser for his resolution and
Vendor shall get the purchasers written resolution.
1.3
Deviations
Any deviation from this specification and relevant documents shall be presented in
writing to the Purchaser, and a ruling in writing shall be obtained by the Vendor before
proceeding with the affected portion.
Unless specific exception/deviation accompanies by a description of the proposed
alternative is recorded under the heading of Exception/Deviation in the Vendors
proposal, it shall be mutually understood that the proposal is based on the equipment
with the requirements of this specification and relevant documents.
1.4
Equivalent Materials
Wherever material requirements are specified as make or equal, the Vendor may
propose equivalent material which shall fully meet the technical and environmental
requirements; such fulfillment shall be proved by documentary evidence supplied by the
Vendor. However in these cases, the final selections of material are subject to Client
approval.
1.5
Vendor Responsibilities
Vendor is responsible for design, supply, manufacturing, and testing based on project
design documents. Compliance by the Vendor with the provisions of this specification
does not relieve the Vendor of the responsibilities for furnishing equipment of proper
design, mechanically and electrically suited to meet operating guaranties at the
specified service conditions.

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 5 of 42
The instruments shall be of the same model and design as used in similar climate
conditions for at least three (3) years and proved satisfactory. Prototype or experimental
instruments are not acceptable.
1.6
Language and Units

All documents and drawings produced by the Vendor to satisfy the requirements of this
specification shall be in the English language.
Operating, maintenance and commissioning manuals shall be also prepared in the
English language.
All dimensions and ratings shall be in metric system (SI: International System of Units)
except for temperatures which shall be in degrees Celsius (oC) and piping sizes, tubing
sizes, fitting sizes and valve dimensions, which shall be in imperial units (Inches).
2. Applicable Documents
2.1
Codes and Standards
The FGS shall be designed, manufactured and tested in compliance with the latest
revision of all relevant international codes and standards including but not limited to the
following:
BASEEFA
(BRITISH APPROVALS SERVICE FOR ELECTRICAL

EQUIPMENT FOR FLAMMABLE ATMOSPHERE)
BSI
BSI-5343
BSI-5445
BSI-5760
BSI-5839
BSI-6020
(BRITISH STANDARDS INSTITUTES)

Specification for Short Term Gas Detector Tubes
Automatic Fire Detection System Parts 1,2,5,7,8 and 9
Reliability of Systems, Equipments and Components
Fire Detection and Alarm Systems for Buildings Parts 1,2,3,4
and 5
Instruments for the Detection of Combustible Gases
CENELEC
(EUROPEAN COMMITTEE FOR STANDARDIZATION)
EIA
RS232C and RS485
(ELECTRONIC INDUSTRIES ASSOCIATION)

Interface Between Data Terminal Equipment and Data
Communication Equipment Employing Serial Binary Data
Interchange
EN
EN-54
EN-50014
EUROPEAN NORM
Components of Automatic Fire Detection Systems
Electrical Apparatus for Potentially Explosive Atmosphere
General Requirements
IEC
IEC-60529
(INTERNATIONAL ELECTROTECHNICAL COMMISSION)

Classification of Degree of Protection Provided by Enclosures

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
Project No : 2260
Rev.
03
Page 6 of 42
IEC-60331
IEC-60332
IEC-61000-4
IEC-60079-14
IEC-60432
Tests for Electric Cables Under Fire Conditions - Circuit Integrity

Tests for Electric Cables Under Fire Conditions - Circuit Integrity
Electromagnetic Compatibility
Electrical Apparatus for Explosive Gas Atmosphere
Conduit for Electrical Purposes
IEEE
(INSTITUTE
OF
ELECTRICAL
&
ELECTRONICS
ENGINEERS)
Surge Withstand Capability Tests
Guide for Surge Tests
Electromagnetic
Interference
and
Field
Strength
Instrumentation
Electrical Transient Protection
Standard Digital Interface for Programmable Instrumentation
Local Area Network Carrier Sense Multiple Access with
Collision Detection
Bus Oriented Token Passing Network
IEEE-C37.90.1
IEEE-C37.90a-1974
IEEE-C63.2
IEEE-472
IEEE-488
IEEE-802.3
IEEE-802.4
ISA
ISA-55.1
ISA-84.01
ISA-S12.13
ISA-S12.15
(INSTRUMENTATION
SYSTEMS
&
AUTOMATION
SOCIETY)
Instrument Symbols and Identification
Binary Logic Diagrams for Process Operations
Graphic Symbols for Distributed Control/Shared Display
Instrumentation, Logic and Computer Systems
Instrument Loop Diagrams
Annunciator Sequence and Spec.
Compatibility of Analogue Signals for Electronic Industrial
Process Instruments
Hardware Testing of Digital Process Computers
Safety Instrumented Systems
Performance Requirement for Combustible Gas Detectors
Performance Requirement for H2S Gas Detection Instruments
NFPA
NFPA-70
NFPA-72
NFPA-30
(NATIONAL FIRE PROTECTION ASSOCIATION)

National Electric Code
Auxiliary Protective Signaling Systems for Fire Alarm Services
Flammable and Combustible Liquid Code
API
API 2001
AMERICAN PETROLEUM INSTITUTE

Fire Protection in Refineries
ISA-5.1
ISA-5.2
ISA-5.3
ISA-5.4
ISA-18.1
ISA-50.1
NIOEC


Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 7 of 42
3. Definitions and Abbreviations
1oo1
1oo2
2oo2
CCR
CPU
EMI
ESD
EWS
FAT
FGP
FGS
HMI
HVAC
IS
I/O
LAN
LCD
LCP
LED
LEL
MCP
OAT
OCD
OCS
PCS
PLC
RAID
RFI
SAT
SIF
SIS
UCP
UPS
One out of One

One out of Two
Two out of Two
Central Control Room
Central Processing Unit
Electro-Magnetic Interference
Emergency Shut Down
Engineering Work Station
Factory Acceptance Test
Fire & Gas Panel
Fire & Gas System including all associated components, field
detectors and electronic modules, PLC Hardware, firmware,
software configured to function as a system in conformance with
this specification and provided by Vendor under this Order. Also
included are all documents, plans, Specifications, Spare Parts,
tools, testing and calibration equipment, manuals, consumables
and other tangible materials as more particularly described in this
Order.
Human Machine Interface
Heating, Ventilation, and Air Conditioning
Intrinsically Safe
Input/Output
Local Area Network
Liquid Crystal Liquid
Local Control Panel
Light Emitting Diode
Lower Explosion Limit
Manual Alarm Call Point
Operational Availability Test
Operator Control Desk
Operator Control Station
Process Control System
Programmable Logic Control
Redundant Array of Independent (or Inexpensive) Disks
Radio Frequency Interference
Site Acceptance Test
Safety Integrity Function
Safety Instrumented System
Unit Control Panel
Uninterruptible Power Supply


Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 8 of 42
4. Overview
5. General Requirements
5.1
Environmental Conditions
Indoor temperature and relative humidity (RH) is +15 to +30 (oC) and 30% to 70%
respectively and shipping and storage conditions will be considered as -20 to 60 (oC)
and 0% to 100%.
For outdoor conditions temperature and relative humidity (RH) is -28 to +43 (oC) and
max. 73%
Allowable indoor noise level shall be considered as 55 dBA, measured at one meter
from equipment in question.
5.2
Hazardous Area Classification and Ingress Protection
Control Rooms, Rack Rooms, Remote Instrument Buildings (RIB) and Substations shall
be considered as non-hazardous areas. All above mentioned rooms will be airconditioned and pressurized.
Indoor stations and equipments and system cabinets shall confirm to IEC-60529, IP42,
as a minimum. Electrical accessories, cabling and junction boxes in hazardous areas
and rooms Like Battery Rooms shall normally be of intrinsically safe construction and
execution suitable for NEC Class I, Division I, Group B, T3 (IEC Zone-I, Group IIC)
locations. All flame proof devices and area classification have been specified on Fire &
Gas Detection System Index. Application of instruments of explosion proof type is
acceptable where the intrinsically safe instruments are not available in the market.
5.3
Electrical Power
5.3.1
Primary Power Supply

The UPS is out of the FGS Vendor scope of supply. The equipment will be normally
powered from dual redundant Un-interruptible Power Supplies (UPS). The UPS will
provide 120VAC2%, 50Hz1%. However all system modules shall be capable of
operating during voltage variations up to 10% and frequency variations up to 5%.
Redundant 24 Vdc power supplies shall be used to power the FGS equipment, switches
and field transmitters. The UPS shall be capable of sustaining all components of the
system for a limited period in the event of total power generation failure. After that the
battery backup as a secondary power supply inside the FGP will provide the power
supply to panel and field devices.
The FGS Vendor shall clearly indicate in his proposal for the following specifications:
Allowable voltage variations
Allowable frequency variations
Allowable distortion
Total power consumption
Allowable duration on momentary power failure
Additionally, provisions shall be available for maintenance of memory contents for at
least 6 month of total AC power failure.

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 9 of 42
A transient power interruption of one-half cycle shall have no effect on the equipment
or system performance.
The Vendor shall incorporate filters, surge suppressers capable of protecting FGS
from voltage spikes.
Others as required by the UPS Vendor.
The Purchaser will prepare the grounding system, however the Vendor is required to
specify system earthing requirements such as grounding resistance, required numbers,
grounding current, etc.
5.3.2
Secondary Power Supply

All fire alarm panels shall be equipped with battery backup and charger. The secondary
power supply shall automatically provide power to the protected premises fire alarm
system within max. 10 seconds, whenever the primary power supply fails to provide the
minimum voltage required for proper operation. The battery shall have sufficient
capacity to operate the fire alarm system under quiescent load (system operating in a
non-alarm condition) for a minimum of 24 hours and, at the end of that period, shall be
capable of operating all alarm notification appliances used for evacuation or to direct aid
to the location of an emergency for 5 minutes. The secondary power supply for
emergency voice/alarm communications service shall be capable of operating the
system under quiescent load for a minimum of 24 hours and then shall be capable of
operating the system during a fire or other emergency condition for a period of 15
minutes at maximum connected load. The types of batteries are SLA (sealed lead acid)
to prevent hydrogen gas releasing inside the panel.
5.4
Cable Specification
All cable size and number of core are shown on Fire and Gas Block Diagrams. For
complementary cable specification refer to following clauses.
5.4.1
Indoor Application
5.4.1.1 Signal Cables

Single or multi pairs, primary insulation for rated voltage 300/500 VAC, Conductor from
stranded annealed copper, twisted pair, insulation color code as black and white, each
pair with number identification, 0.5mm2 stranded annealed copper conductors with 0.5
mm PVC insulation, cable shield from aluminum laminated tape, inner/outer cable jacket
from flame retardant PVC material, fire resistance as per IEC-60331, Jacket color for
general use as black and for intrinsically safe as light blue.
5.4.1.2 Power Cables
Two cores, primary insulation for rated voltage 300/500 VAC, Conductor from stranded
annealed copper as per IEC 228, insulation color code as black and red, extruded flame
retardant PVC bedding, fire resistance as per IEC-60331, and over sheath as per IEC
60502.
5.4.2
Outdoor Above Ground Application

All above ground cables which will be installed higher than 1500 mm from above ground
shall be fire resistance as per IEC-60331.

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 10 of 42

Same as 5.4.1.1 but with single galvanized steel wire armoured with 90% nominal
coverage.
Same as 5.4.1.2 but with single galvanized steel wire armoured with 90% nominal
coverage.
5.4.3
Outdoor Buried Application

All under ground cables and above ground cable is installed lower than 1500 mm from
grade is not required to be fire resistance.
03

Same as 5.4.2.1, but with additional lead sheath 1.3 mm minimum average radial
thickness.
Same as 5.4.2.2, but additional lead sheath as seamless tube in accordance with BS
EN 12548, with minimum average radial thickness as per IEC 60502-1 and not less
than 1.2mm.
5.4.3.3 Fiber Optic Cables
Fiber optic cable, 4 cores, 50/125 microM, multi mode, attenuation @ 850 nm app. 3
db/km, @ 1300 nm app. 1 db/km, steel wire armoured and additional lead sheath 1.3
mm minimum average radial thickness.
5.5
Noise Immunity (RFI/EMI)

Equipment shall meet all electromagnetic compatibility requirements of the IEC-610004-2, 61000-4-3 and 61000-4-4 standards.
Each element of the system provided to meet the requirements of this specification
must function without introducing intolerable electromagnetic disturbances to other
items or being susceptible to electromagnetic influences from other systems.
Emission limits generally comply with the relevant requirements of BS-6527 for class B
equipment, and susceptibility performance shall generally comply with the relevant
requirements of IEC-1000-4. All equipment comprising the system shall be designed in
such a way as to ensure immunity to interference from VHF and UHF hand portable
transceivers operating in the range 150MHz to 470MHz with power output of 1 Watt
(RMS) held at 300mm from any equipment forming part of the system.
5.6
Reliability of Fire & Gas System

The system shall be required to work on continuous 24 hours every day, 7 days a week
basis. It is therefore crucial to have a high degree of reliability and availability in both
hardware and software to ensure that the system operates as intended and when
required. Spurious operation and consequential disruption of the plant operations must
be avoided to maintain a high degree of confidence in the system.

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 11 of 42
To achieve this, the equipment shall ensure complete autonomy, employ necessary
redundancy where applicable, be of fail safe design and ensure that a single component
failure will have a minimal effect on the overall equipment availability and employ
proven technology.
The availability and reliability report of the FGS equipment, including MTBF figures,
shall be included in the Vendors proposal.
This is discussed in greater detail in the following section:
5.6.1
General
The FGS shall provide adequate information and control in the event of component
failure, system testing, maintenance or replacement of equipment. Three critical factors
can be highlighted: Reliability, Availability and Maintainability.
5.6.2
Reliability & Availability Predictions

Reliability and availability prediction shall be provided by the Vendor for each system
unit and for overall system.
Basic failure rate figures ( ) of the units used in the system shall be calculated.
The Vendor shall specify the source of reliability data used (component manufacturers
databases or other available component databases).
All calculations shall be based on the actual system configuration.
The main task shall be to identify faults that will affect the system function. Any
assumption made by the Vendor shall be detailed explicitly in the bid.
The availability shall be evaluated as:
A=
MTTF
MTTF + MTTR
Where,
A=Availability
MTTF=Mean Time To Fail (1 / )
MTTR=Mean Time To Repair
All calculations shall be made with MTTR of not less than 2 hours.
5.6.3
Fault Tolerance
The system shall not be fooled by fault conditions within itself or by spurious signals
from sensors. In other words, the system shall be fault tolerant.
A shutdown which has been caused by a system fault, instead of abnormal process
condition, is called a spurious shutdown.
A fault tolerant system is one that avoids spurious shutdowns or nuisance actions and
creates a high level of confidence for users.
The redundant modular system shall be configured for a 2oo2 voting process. If an
output disagrees with the other, it is assumed that one sensor has failed. Diagnostics
within the system shall assist when troubleshooting to find faulty sensor.
A single failure within a redundancy may degrade the reliability for that function. The
degraded function will be allowed to operate at a degraded level for a pre-defined period
of time as long as the safety function is sufficiently monitored.


Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 12 of 42
6. Design Philosophy
6.1
General
The FGS shall be dedicated system that, upon detection of an abnormal condition or
manual action, shall initiate and perform pre-defined actions which are necessary to
bring the process/utility to a safe state. This shall be done in accordance with the
approved FGS cause/effect matrix and logic diagrams. Such abnormal conditions may
be caused by fire or gas hazard. Effective and early detection of potential hazard on
installations is extremely important considering the safety of personnel and equipment.
Hazardous conditions could occur due to leakage of flammable gasses and/or process
malfunctions. Monitoring of hazardous conditions shall be such that executive protective
actions could be initiated before the situation is out of control.
6.2
System Architecture
The FGS system is configured to communicate signals monitored/controlled between
Main Control Building, Existing and New Fire Stations and field locations through
Remote Instrumentation Buildings (RIB) or Substations.
The system is analogue addressable and field manual call points will be addressed in
dedicated FGP. For inside the buildings detection is conventional and fire zones status
will be interfaced by local zone monitors to allocated FGP. All necessary interface
module such as zone monitors, switch monitors, and I/O modules and etc. shall be
installed on local junction box within buildings.
The system shall comprise of different types of flame, smoke, heat and gas detectors,
manual call points, manual releases, alarms, horns and etc. which shall be connected
by hard wire to local F&G panels and cabinets in RIBs or Substations.
Each local FGPs shall be interfaced with main FGP installed in main control building
and newly installed FGPs in existing fire station and new fire station through redundant
fiber optic communication network. (Refer to Overall Fire & Gas System Configuration
Diagram #AK-00-9001-1/1)
For specifications of power supply, processor, and I/O modules, there is no difference
between main FGP in control building with other local FGPs. Only difference is in fire
suppression control module and remote actuation of fire fighting systems. Regarding the
authority for operation of fire fighting system should be considered in one operation
center, this capability is foreseen on main FGP in main Control building only, and other
local FGPs do not have this facility.
All fire detection circuits, alarm circuit and command signals shall be monitored for
continuation and short circuit of interconnections. It will be done by putting end of line
resistor for last elements on each circuit.
The FGS system shall be based on redundant PLC technology and there is no interface
with the Process Control System and Safety Instrumented System. The FGS system
shall be interfaced directly with following devices, but not limited to:
INPUTS
Smoke &Heat Detectors

Manual Call Points
Flame Detectors
Gas Detectors

Upgrading Project
Job Specification
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Document No.
SP-2260-90-421-3
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Project No : 2260
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Page 13 of 42
Pressure & Limit Switches

Manual Release Stations
Local Fire Alarm Panels
Auto/Manual/Inhibit Switches
OUTPUTS
Solenoid Valves
HVAC Panels
Bell, Alarms and Horns
Flashing Lights and Sounders
Exit Lighting Panels
No Entry Lighting Panels
Door Holder
Smoke/Fire Damper
Motor Siren
The system shall be able to monitor all sub-circuits and FGS logic while in normal
operation. This shall consist of internal and external fault monitoring. A comprehensive
monitoring scheme shall be provided to reveal the faults as soon as they occur. The
diagnostics and repair shall be carried out without the process being disturbed.
Software reliability shall be considered in order to reduce the effect on the overall
system reliability. The analysis shall be based on:
Minimizing the use of diverse software

Utilizing high quality software
Minimizing software modification/updating
The system shall be responsible for the logic evaluation of the signals derived from the
detection devices, including any voting.
Depending on the evaluation, the system shall issue all components to the Fire Fighting
Systems and to the Emergency Shutdown System.
6.2.1
Fire & Gas Operator Interface
6.2.1.1 Operator Interface in Main Control Room

A Dedicated FGS operator console shall be provided in the Main Control Room. The
console shall be graphic based with keyboards and printers to facilitate full operator
interface with the system to perform monitoring, override operation, alarm logging and
system diagnostics etc.
6.2.1.2 Operator Interface in Existing and New Fire Stations
A Dedicated FGS operator console shall be provided in the existing and new fire station
buildings. The console shall be graphic based with keyboards to facilitate full operator

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 14 of 42
interface with the system to perform monitoring, exchange signal and announce fire
brigades.
6.2.2
Communication Links
A dedicated redundant data link shall be provided to link the FGS system cabinet to the
console provided for Main Control Room and Existing and New Fire Stations.
6.2.3
Interface with Emergency Shutdown System

Regarding the automatic shutdown of process is not conceived, so interface of FGS
with SIS system is not required. In case of fire event, gas detection or any emergency
case, the emergency shut down will be taken manually through operator within control
building.
6.3
FGS Panels Configuration

Electronic modules of the system shall be located in cabinets housed in Rack Room (for
main F&G Panel) or RIBs and Substations. The system shall be based on PLC
technology and shall be redundant in all parts; including the power supply, processor,
and communication interfaces.
The system shall be equipped with maintenance override commands which will facilitate
calibration and maintenance work without causing spurious alarms.
The system shall employ 2oo2 voting techniques as follows:
6.4
Dual automatically redundant and independent processors. Each processor shall

execute its individual program simultaneously and independently (executing logic
instructions, control calculations and clock and voter synchronization)
The operating system and application software shall be stored in non-volatile
memory.
Failed modules within the system shall be automatically detected, identified and
alarmed via output contacts, diagnostic status, and/or LEDs without interrupting of
normal processing functions. These types of failures shall be announced on the
console. The Vendor shall state in his bid how the diagnostics and repair may be
carried out without disturbing the process.
On-line replacement of any system module shall be possible without having to
reconfigure system software, system wiring and cabling or de-energizing system
power.
The system logic shall be fail-safe, energized on alarm state. This implies that in the
non-alarm state, opened input sensor switches shall keep the logic outputs de-active
providing an opened circuit to remote devices such as solenoid valves and relays.
The system shall be required to supply power to external actuating devices such as
solenoid coils, relay coils in the interposing relay panel, etc. The Vendor shall note
the maximum current per channel and/or module in their quote.
System CPU
The system operating program shall be resident on flash ROM memory. The central
processing units should contain the application program in non-volatile memory.

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If the application program in kept in a battery backed up memory, then:
A minimum of 72 hours battery backup shall be provided.

It shall be possible to replace the battery while the system is operating without losing
the contents of the memory
An indication of low battery power shall be provided locally by LED and remotely on
system status display.
CPU maximum loading shall be 60% in any condition. The Vendor shall state any
minimum CPU loading requirement in their proposal.
The CPU shall continuously scan the control program stored in memory, along with the
status of all inputs and execute specified commands to the appropriate outputs.
The communication bus should be redundant and deterministic. The switch over time
should be 50 milliseconds or less. The redundant CPU switchover time should be
preferably 5 milliseconds or less, if available.
6.4.1
CPU Hardware Security

A key-lock mode select switch on each CPU chassis shall prevent memory modification
from any outside source. Switching action to/from RUN status of CPU mode must be
alarmed and logged in MCR. Software passwords may also be used.
6.4.2
CPU Status Indicator
6.4.3
The CPU shall be continuously monitor its own status and indicate both normal
operation and error conditions via LED status indicators on each CPU module
faceplate.
Fault condition shall be announced both locally and remotely and logged to a printer.
The monitoring watchdog for the microprocessor should be separate part of the
system that is dedicated to this function only. The Vendor shall provide reliability data
for the watchdog and advise how they avoid malfunction due to common mode
failure.
Monitoring hardware shall be kept as simple as possible, consistent with the need to
provide a system that is at least reliable as the multiple process conditions.
The total system input scan time shall not be more than 50 milliseconds under full
load conditions.
CPU Protection
Power line inputs to the CPU shall be in accordance with IEEE 472.
6.5
Input/Output Modules
Digital inputs shall be designed to receive input signals from FGS detection system
contacts that are opened during normal conditions and will close on fire or gas
conditions. All input/output modules shall be supervised for any rupture or short circuit in
line to field devices.
While no MCP can be bypassed, the rest of input bypass facilities for each input shall
be provided to allow calibration, testing and maintenance. Maintenance bypass facilities

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shall be activated via the FGS console and shall be announced at the FGS console with
the action an alarm being logged to disk and the FGS console printer.
These types of bypasses are not time dependent and shall have a re-occurring alarm
logged in a similar fashion at a pre-determined rate.
Area bypasses shall be provided to inhibit the action from a building or area when
welding or other work known to cause false alarm in being done. This shall only be done
if there is adequate monitoring of the area affected to manually initiate the required
action in case of fire and alarm condition. These types of bypasses shall be initiated
from FGS console, alarmed, and logged to disk as well as the FGS console printer.
These types of bypasses shall be automatically returned to the normal state after a predetermined period of time with a warning alarm when there is 10 minutes remaining in
the bypass condition.
Input bypass switches shall not bypass outputs to signaling devices, alarm displays etc.
Each FGS point shall be individually fused and rated at the same voltage as the
input/output module. These fuses shall be replaces in a location readily accessible for
maintenance. The number of channels for I/O cards shall be a maximum of 16 and shall
have LED status indication on all input/output channels.
6.5.1
Output Isolation Relays

Isolation relays shall be used for multiplication of FGS inputs and outputs unless they
are specified to be essential for:
Isolation of different input or output signals such as motor control circuits

Preventing the mixing of circuit voltage/currents
Relays shall be miniature, hermetically sealed devices, with a minimum of 2 changeover

contact sets. The coil shall be equipped wit a LED to indicate coil status and a
suppresser diode.
6.5.2
Ground Fault Detection Circuitry

A ground fault detection circuit shall monitor floating electrical circuits in filed wiring.
Ground faults shall be announced via an alarm indicator in the control room.
Discrete ground fault detection modules (if used) shall be rail mounted and installed in a
location readily accessible for maintenance.
6.5.3
I/O Protection
Input circuits shall be type-tested for surge-withstand capability in accordance with ANSI
C 37.90.
Output circuits shall be provided with protection against the switching of inductive loads
(i.e. solenoid valve coils) and protection against current overloads.
6.6
Communication Interface
The system shall support standard means for communication with external devices as
the PCS, SIS and LAN, etc.

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All communication parts shall permit connection and disconnection without interrupting
operation.
Communication ports shall be configured to operate redundantly and accommodate
redundant media.
External communication shall be provided by means of electrically isolated
communication interfaces with redundant communication ports and paths. Said
interfaces shall be powered by the system itself and shall use standard industrial
communication protocols, set by ISO and IEEE.
The FGS shall interface to the PA/GA to initiate the alert tones in the event that a
specific shutdown category of fire firefighting actions has been initiated.
6.7
Operator Interfaces
The required facility and standard output terminal shall be provided for connecting FGPs
to operator workstations as specified in 6.2.1. The supply of console, LCD monitor and
keyboard is excluded of FGS Vendor. For consistency with other PCS consoles in main
control room, they should be provided by SIS and PCS system Vendor. The console
shall consist of monitor/keyboard based stations and hardwired auxiliary consoles with
lights and push buttons. The auxiliary console is shared with the CCTV.
6.7.1
Hardware
6.7.1.1 FGS Console

The FGS console shall consist of the followings:
LCD monitor, 19, antiglare, low radiation, non-capacitive, minimum 16 distinct colors
Industrial Grade Keyboard, spill or dust proof membrane, C/W manufacturers
standard layout
Communication Interface to Dual Redundant Communication Link
A dedicated printer shall be provided to log all faults, status and hazard alarms for the
FGS system. As the printer should be used infrequently, a message stating the
systems Health should be sent to the printer at a suitable frequency so as to ensure
it is operational.
Printer shall have a self-test feature and a printer buffer (in memory) shall be provided to
allow uninterrupted operation of workstations while any printer in operating including the
printing of graphic display.
The Vendor shall specify the maximum allowable distance between the workstation
electronics and printer itself.
6.7.1.2 Hardwired Main Auxiliary Console
Due to multiplicity of manual actuation of active fire protection systems such as CO2 total
flooding systems inside the substation/RIBs, inert gas extinguishing system inside the
control buildings, and water deluge systems around equipment in process units and
tankage area no push button for actuation of above system is not foreseen on FGS
console. So all of them shall be considered on front face of FGP in rack room in main
control building.


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6.7.1.3 Operations and Functions

The main control room shall be made fully aware of the hazardous conditions at all times
to enable the operator to pinpoint the source of hazard and take necessary actions.
Features employed on the workstation shall be as follows:
FGS confirmation from field

Indication when input field detectors have cleared the alarm conditions
Alarm and signaling for common status of equipment system, etc.
I/O override functions
System status; typically CPU, I/O cards and power supplies
Reset functionality cannot be initiated from this console
6.7.1.4 Alarms
All alarms shall be shown on the screen by a flashing red point, accompanied by an
audible warning (buzzer). Alarm handling shall confirm to ISA-S-18.1 with manual reset of
alarms following acknowledge and input retuning to its normal state.
6.7.1.5 Final Control Element and Equipment Status
Final control element (on-off valves, etc.) status may be indicated on the screens by
easily recognizable symbols as per ISA-S-5.4. These symbols shall start flashing upon
respective activation and turns to steady state when the final control element returns o its
safe position. A descriptive and dynamic text box shall be located near the symbol to
describe the state, i.e. OPEN, TRAVEL, RUNNING, STOPPED, etc.
6.7.1.6 System Status (CPU, I/O Cards, etc)

System diagnostics shall be presented on the screen with flashing points in alarm
condition, turning to steady state upon alarm acknowledgement. The buzzer shall also be
activated upon a system fault.
6.7.1.7 Alarm Event Handling
All FGS alarms/events shall be recorded and printed out in the same chronological order
as they are received by the system.
6.8
FGS Monitoring & Control System Software
6.8.1
Security
Different levels of password shall prevent memory programs modification from any
external source (hardware protection key may also be used).


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6.8.2
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Programming
Engineering/Programming shall be done via the engineering console to develop the
control program, to diagnose system status, and if necessary, to force points for loop
check or maintenance of field sensors.
Programming shall be as simple as possible through the use of common functional
blocks.
Program editing function shall incorporate automatic time-date and revision level file
saving routines.
Programming development software shall be capable of supporting both on-line and offline programming.
Methods for off-line debugging and program simulation in the development station shall
be possible.
6.8.3
Software Utilities
The following software utilities/tools or equivalent functions shall be provided by Vendor
as a minimum (the programming tools shall be per IEC 61131):
Industry Standard Relay ladder Logic

Boolean Operators with Timing and Voting Functions
High Level Language (Structured Text)
System Diagnostics
On-line Data Changes
Chronological Events Recording (CER or SOE) Software
CER (or SOE) Printing Function
The use of Sequential Function Charts (SFCs) shall not be permitted.
6.8.4
Configuration
The Vendor is required to develop application programs which perform the logic
sequence and functionality as indicated on the Cause and Effect Matrix supplied by the
Purchaser.
The application program shall be structured to keep similar programming features
grouped together.
The following sequence of grouping is suggested:
Analogue data value to engineering unit conversation: to simplify programming,
perform the conversions calculations at the beginning of the program.
Common data calculations: if certain calculated values are required repeatedly
through the program, perform the calculations once and utilize the resulting register
value as needed.
Common internal coils: if grouping of the same input contact are used repeatedly
through the program, combine them into common internal coils for easy programming
and memory saving.
Data which is interfaced to external system should be grouped together to facilitate a
block transfer of data.


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Sufficient commands and descriptions shall be included throughout all logic networks to
help operators and maintenance personnel.
6.8.5
Diagnostics
Each CPU shall incorporate self-diagnostic routines, I/O status checks, loop-back
verification and watchdog timer to determine the health of each module within the
system.
For redundant modules, comparison fault detection shall be performed using 2oo2
voting.
These routines shall automatically identify alarm, isolate and contain faults without
compromising system performance.
Diagnostic features shall run without interfering with application program, scan or
execution time.
On-line diagnostics shall be capable of:
6.9
System Cabinets
6.9.1
Cabinet Construction
Checking voter and fault detection

Verifying all RAM and ROM controls
Verifying the integrity of the operating system and application programs while running
Fabricate the control panel from 5mm (minimum) cold rolled steel, formed members
except for the 100m channel base frame. Make or fabricate the main panel front and
upper section insert of 12 to 13mm thick phenolic sheet. Colour to be vista green with
walnut ends.
Panel structure shall be entirely self supporting by the use of 50mm structural angle
iron frame. Framing and brackets shall be as necessary to achieve a rugged design
and to insure a smooth, flat surface with a maximum deflection of 4mm over total
surface of panel after installation of all instruments and accessory equipment. Holes
shall be provided at panel joints complete with bolts, nuts, and washers for panel assembly. The entire unit shall be shop-assembled and be checked for accurate
alignment and surface matching.
End plates shall be provided as removable.
Bottom rear of the panel shall be easily accessible.
The top section of the panel board shall be a medium density semi-graphic display for
each panel unit.
For handling purposes, each shipping section shall be provided with removable lifting
lugs designed for lilting without deforming the panel.
About 20% space shall be left unoccupied for future installation. Void spaces shall be
closed by a cover.
Each cabinet cell shall be self-standing type with front/rear access and overall
dimensions shall be 2100x800x800 mm (H x L x W).
Construction criteria and internal equipment layout shall guarantee a high degree of
safety, reliability, accessibility and maintainability. Ingress protection shall be min. IP42.


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6.9.2
Project No : 2260
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Access doors and frames shall be with lift off type hinges and retraceable handle with
internal lock. All locks shall be supplies with a minimum of four spare keys. All
cabinets shall be keyed identically. Both the doors shall have a cabinet identification
tag fixed by stainless steel screws.
A copper bar for the cabinet ground shall be provided for easy connection to the
external grounding system. An insulated copper bar, for cable shielding grounds,
shall be provided for each cabinet.
Each cabinet shall be provided with an internal non-fluorescent type lamp with an
automatic door switch and socket outlet powered from a separate UPS circuit and
feeder breaker. The socket shall be suitably labeled as for electronic equipment use
only.
Cable entries shall be from bottom. The cabinet base shall be fitted with two M-12
earthing bonding lugs. The cabinets shall be designed for bolting to the plinth via anti
vibration mounting.
Power supply units shall have a lamp on the cabinet front indicating a power supply
failure, a voltage free contact with the same function shall be provided for remote
monitoring.
Ventilation System
NIOEC
6.9.3
Cabinets shall be provided with an internal ventilation system, in order to extract the
heat produced by electronic circuits assuring that all devices properly work in the
specified temperature range.
A temperature reading system shall also be provided to generate an alarm signal (in
the MCR) in case the temperature inside the cabinet exceeds the set value.
Fans shall be suitable for continuous operation and mounted on self lubricated
bearings. Filters for ventilation shall be of the easily replaceable type.
Vendor shall state if temperature sensor or smoke detector inside the cabinet are
required.
Wire Termination
The system cables between the barrier cabinets and the system cabinets shall be
supplied by the Vendor in the prefabricated form and pre-connected at the FGS
Vendor factory to the respective cabinets.
Termination boards shall be provided with suitable (Multi-pin) input/output connectors
for quick interconnection.
All terminal blocks shall be suitable for rail mounting with screw compression type
conductor terminations. The material employed shall be non-flammable
Terminal blocks within the system shall be knife type with built in fuses for each
powered I/O on an individual basis.
More than two wires shall not be connected to a single terminal block connection. The
second wire, if necessary, shall be a jumper wire to another terminal.
Terminal blocks shall be segregated in the following types to allow quick identification
of wires:
Analogue inputs
Discrete Inputs

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Discrete Outputs
Communications
Power Supply
Internal Wiring
6.9.5
NIOEC
I/O and interconnection wiring shall be tagged at each end with the identification tags.
Self-adhesive type markers are not acceptable.
Cable insulation shall be flame retardant type (IEC 60332).
Wiring and related cable-entry shall be segregated in the same groups of
terminations.
Internal DC Power Supplies
A dedicated redundant power supply unit shall be provided to feed power to racks of the
system.
Each power supply unit shall be sized to provide 130% of the required capacity (at rated
voltage) for the specified configuration of I/O cards and CPUs including installed spare
modules.
Field voltage supplied by the FGS I/O modules may vary within the following limits:
24 Vdc 10%
Each power supply unit shall have built in diagnostic circuitry to monitor out of range
voltages and over-temperature conditions.
Each power supply unit shall have its own internal fuse/circuit breaker protection on the
incoming line side.
The Vendor shall carry out a fuse co-ordination study to ensure that in case of a short
circuit only the directly protecting fuse or circuit breaker interrupts the circuit and no
higher level fuse melts or circuit breaker opens.
Each power unit shall feed a separate power rail.
Separate dedicated system grounding is not desired. If the Vendors system requires
dedicated grounds, the proposal shall include sufficient information to determine how
these grounds are to be arranged.
The Vendor shall include sufficient heat dissipation requirements in the proposal so that
air conditioning can be sized.
The Vendor shall include the power load requirements in the proposal so that the
battery system can be sized.
Power supply unit status shall be indicated on its face plate and shall be remotely
communicated via alarm contacts and software.
6.9.6
Installed Spares
The following spares shall be provided:
20% average installed I/O cards, CPU, Memory and terminals
20% average space inside the cabinets area wise
6.9.7
Name & Tag Plates

Each instrument, equipment, cabinet and panel included in the Vendor scope of supply
shall have its individual name and tag plate.
All name and tag plates shall be designed and supplied by the Vendor.

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The plate shall be provided as listed below:
A nameplate for each instrument or auxiliary device shall be provided on rear of

panel. For these nameplates, use tag numbers only.
Indoor plates shall have white text on black plastic plates.
Outdoor equipment shall have engraved type, corrosive resistance, stainless steel
plates.
Plates shall be securely fixed at both ends with stainless steel screws.
Plate size, characters font and character format shall be submitted for the Purchaser
for review and approval.
English lettering shall be used.
The Vendor mark and nameplate shall also be required for each equipment interface
console, cabinet and rack containing the manufacturers name, manufacturing date and
production number. The material and format shall be the same as other nameplates as
discussed above.
6.9.8
Painting & Rust Prevention
6.10
All burrs produced around cutouts or bolt drilling holes must be ground smooth.
Steel panels shall be sand blast. After fabrication, all welds should be ground smooth.
A minimum of two finish coats shall be applied, based on the type of paint to be used
so as to present a good smooth non glare finish.
Colour of finished paint for outside of the panel shall be in accordance with RAL3020
as Fire Red.
The inside of the panels and racks as well as any supporting brackets, mounting
plates, etc., shall be cleaned, primed and finished with flat white paint.
FGS Devices
6.10.1 General
All areas where the detection of abnormal conditions shall initiate automatic executive
such as release of gas extinguishing agent as specified by the Cause & Effect Matrix,
shall have minimum of 2oo2 coincident detectors.
The operation of a single detector, 1oo2 shall be displayed and announced in the main
control room. Simultaneously operation of any two detectors within the same zone
(2oo2 voting) shall automatically initiate the required executive action.
The selection of type and placement of the FGS detectors shall be accomplished in
such a way that as far as possible and practical, the latent detection time is minimized
but still no malfunction will be caused by temperature, wind, humidity, lightening, solar
radiation, dust or vibration.
Each protected area shall be provided with suitable facilities to allow the inhibition of
control actions during maintenance and calibration while the system is in operation.
Standard calibration gas required for periodic sensor calibration/checking and
troubleshooting shall be specified by the Vendor and supplied in sufficient quantity until
commissioning activities are over.


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6.11
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FGS Field Devices
6.11.1 Flammable Gas Detectors

Flammable gas detectors shall be flame proof, EExd or EEXed, Div.1, IIC, T3, IP 65,
transmitter with 4-20 mA output signal, microcontroller based operation, backlit LCD
indication for gas hazard level and sensor status, digital and analogue signal outputs,
diagnostic and self test facility, supply voltage 10-32 VDC three wires, constructed for
harsh environmental and corrosion resistance, terminals for 6X4.0 mm2, cable entries
2 bottom entry M20, design and manufacturing in conformity with ISA-S12.13.
The gas detection system should have two nos. independent alarm set points which can
be set between 0 to 100% of the indicated Lower Explosion Limit (LEL). The lower set
point should be considered at 25% of LEL and upper set point at 50% LEL. It shall be
possible by simple means to perform a calibration of each detector and test alarm level
without interpreting the process. The response time shall be less than 10 seconds.
Due considerations shall be given to the installation level and influence of ambient
conditions on gas detectors.
6.11.1.1 (CH4) Gas Detectors
All areas of the installation, where gas leakage is possible, shall be monitored by
methane (CH4) gas detectors.
At least following equipment which handles flammable fluid shall be protected with CH4
gas detectors:
Sphere Tanks: Two (2) for each tank (Upwind and Downwind)
C3/C4/LPG Pumps: One for each set of pump
Process compressor handling hydrocarbon products: Two(2) for each upwind and
down wind
6.11.1.2 (H2) Gas Detectors

Battery rooms shall be protected with H2 gas detector. In addition compressors
handling hydrogen gas shall be protected with H2 gas detectors upwind and down wind
of compressor.
6.11.2 Toxic Gas Detectors
Toxic gas detectors shall be microprocessor based and same as general specification
mentioned in clause 6.11.1.
6.11.2.1 H2S Gas Detectors
For the equipment/facilities where gas containing high H2S concentrate is handled, H2S
gas detectors shall be provided.
For the single equipment which handles gas containing 1000 ppm or more H2S, one
(1) detector shall be provided close to the equipment.
For group of equipment or facilities where gas containing 1000 ppm or more H2S is
handled, detectors shall be provided surround the area of the group with 15-20
meters interval.
The detector will not be installed on the structure but installed at the round level
instead, since H2S gas is heavier than air and easily spread to the ground level.

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The H2S detectors shall be direct installation type without the need for sampling system.
They shall be protected using a permeable stainless steel sintered disk and shall be
poison resistant. Sensor replacement shall be easily made by using a permanent base
and plug-in type connector.
The H2S sensors should be connected to gas cards that shall be capable of displaying
the gas concentration in PPM and generate alarms at the desired set point.
The range of sensors shall be 0 to 50 PPM.
Two independent alarms with the set point adjustable from 0 to 100% of the range shall
be provided. Alarm levels shall be provided at 5 PPM and 10 PPM.
6.11.2.2 CO Gas Detectors
For the equipment/facilities where CO spread in expected, CO gas detectors shall be
provided.
In this plant the RFCC unit (Regeneration Section) and No.2 Hydrogen Production Unit
are the CO gas sources where CO gas detectors shall be installed.
Detectors shall be installed near the equipment of facilities where CO leakage is
expected.
The CO sensors should be connected to gas cards that shall be capable of displaying the
gas concentration in PPM and generate alarms at the desired set point.
The range of sensors shall be 0 to 400 PPM.
Two independent alarms with the set point adjustable from 0 to 100% of the range shall
be provided. Alarm levels shall be provided at 50 PPM and 100 PPM.
6.11.3 Flame Detectors

Flame detector shall be UV/IR, outdoor installation, flame proof, EExd, Div.2, Gr.
D,T2, 0-20 mA output signal, self test feature, aluminum housing, 20-36 VDC power
supply from fire alarm control panel, selectable sensitivity, min. 30 m solid cone of
vision for propane and butane fires, 6 sec. average response time, suitable for
ambient temperature -28 to 43 deg and 73% relative humidity, constructed for harsh
environmental and corrosion resistance, 8X2.5 mm2 terminals, one bottom cable entry
M20,with cable gland, for steel wire armoured and lead sheath PVC cable along with
adjustable mounting bracket, and tag no. name plate.
Some areas of the plant in which a fire may occur shall be provided with a suitable fire
detection system. Detectors shall be used for fast detection of a fire. The detectors shall
be of the restorable type such that after activation they can be restored to normal
surveillance without the renewal of any component.
The detectors shall be microprocessor based.
UV/IR Type flame detectors operating on 2oo2 basis, flame flicker circuits should be
provided to reduce noise due to solar or man made interference. Response time shall
be less than 15 seconds and detection range shall be within 0.1 to 15 meters.
The detector shall incorporate a latching LED indication which when illuminated,
indicates the detector is in an alarm condition. The LED must remain illuminated until
the alarm condition has been reset.
Flame detectors shall be provided to the sphere tanks to detect fire and activate water
spray system automatically.
The detectors for each top and bottom main nozzle (total 4 sets) will be provided, since
these nozzles are the most probable source of fire.


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6.11.4 Linear Heat Detectors

Linear heat detector cable shall be digital and fixed temperature 75 deg. C, flame proof,
intrinsically safe, suitable for EExe, Div.2, Gr. D,T2, two twisted steel conductors with
heat sensitive polymer coated, outer cable sheath suitable for outdoor installation and
UV resistance, flame proof junction box suitable for ambient temperature -28 to 43 deg
and 73% relative humidity, constructed for harsh environmental and corrosion
resistance, with tag no. name plate, design and manufacturing in conformity with NFPA72 or BS5839 or EN.
Electrical linear heat detectors shall be provided to activate the deluge systems for the
equipment or group of equipment other than sphere tanks.
When heat sensor (electro sensitive linear heat detector) which is composed of two
twisted wires with special coating senses the fire by burning the wire coating and
making a short circuit, this signal via zone monitor module will be transferred and
addresses the activated linear heat detector on FGPs. In case of automatic actuation
specified in Cause & Effect Matrix, the related deluge system will open automatically.
Linear heat detector shall be provided to each group of following equipment to activate
deluge/spray system:
Horizontal vessels containing C3, C4, LPG or flammable liquid such as Naphta,
condensate, etc.
Pumps handling high temperature (higher than the auto-ignition temperature of the
fluid handled or 260 oC) or high pressure (500 Psig or above) liquid.
Compressor of Hydrocarbon Service
6.11.5 Manual Alarm Call Points (MCP)

Manual call point shall be analogue addressable, outdoor installation, EExd for Div.2,
Gr. D,T2, IP 65, red epoxy color, and UV resistance glass reinforced polyester
enclosure suitable for ambient temperature -28 to 43 deg. C and 73% relative humidity,
constructed for harsh environmental and corrosion resistance, reset by repositioning the
element, switch ratings for 0-30 VDC, 5A resistive, cable entries 2 bottom entry M20,
with cable gland (one is plugged), terminals for 6X2.5 mm2 for steel wire armoured and
PVC sheath cable, earth plate, with tag no. name plate, design and manufacturing in
conformity with NFPA-72 or BS5839 or equal EN.
Every MCP should be located such that one need not cross/enter the hazardous area to
access the MCP. A MCP should not be placed where it can obstruct normal personnel
movement and cause unintentional alarm.
The MCP shall be located so that it should not take more than 50 meters to get to the
MCP in the field.
Manual Alarm Call Points shall be provided in all areas of the refinery.
Activation of MCPs shall activate an alarm annunciation in control room and in local.
Outdoor MCPs shall be break glass and analogue addressable type. They should be
equipped with built-in isolator. However they shall be of heavy duty type single action
with IP-54 as minimum for non hazardous areas and double action explosion-proof IP65 for hazardous areas.
In case of activation of MCPs in field the MCP address will be shown on FGPs.


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Page 27 of 42
6.11.6 Alarm Sounders and Flash Lights

Alarm sounder with Flash lights shall be conventional type, outdoor installation, flame
proof, EExd for Div.2, Gr. D,T2, IP-65, red epoxy color, glass reinforced polyester
enclosure, 24 VDC power supply from fire alarm control panel, replaceable tube, high
intensity flash, low current consumption, suitable for ambient temperature -28 to 43 deg.
C and 73% relative humidity, constructed for harsh environmental and corrosion
resistance, 2 bottom entry cable M25 (one is plugged), terminals for 6X2.5 mm2,with
cable glands for steel wire armoured and PVC sheath cable, earth plate, along with end
of line resistor with tag no. name plate, design and manufacturing in conformity with
NFPA-72 or BS5839 or EN.
Combined fire and gas alarm sounder and flash lights shall be provided for outdoor
locations. The sound level shall be selected such that the alarm can be clearly audible.
Attention shall be paid to areas where high level noise generating equipment is to be
installed. Selectable alarm pattern shall be provided so the alarm will be clearly audible
and distinguishable. The form of audible signal shall be continuous at 600 Hz. Alarm
Horns shall have a minimum sound pressure of 100 dBA at 1 meter and rated for
continuous use.
Flashing lights shall be of Xenon type flashing and self contained with a 360 degree
cone of vision. The lens shall be manufactured from impact resistant polycarbonate or
toughened glass and colored Red for Fire, Yellow for flammable gas and Blue for toxic
gases.
Alarm sounder with flash lights can have a combination of followings:

Sounder with Red Flasher
Sounder with Red and Yellow Flasher
Sounder with Red and Blue Flasher
Sounder with Red, Yellow and Blue Flasher
The application of lens colors is as Red for fire, Yellow for flammable gas, and Blue for
toxic gas.
The minimum intensity for lights shall be considered 635 cd and shall not exceed 1000
cd.
Alarm Horns and Flashers should be suitable for explosive atmosphere classification.
6.11.7 Motor Sirens

Motor Siren shall be conventional type, outdoor installation, flame proof, EExd for Div.2,
Gr. D, T2, IP-65, red epoxy color, UV resistance glass reinforced polyester enclosure.
220 VAC power supply, min. 130 db(A), two tones with coverage of 300 m radius,
suitable for ambient temperature -28 to 43 deg. C and 73% relative humidity,
constructed for harsh environmental and corrosion resistance, terminals for 6X2.5 mm2,
1 bottom cable entry M20, with back box, cable gland for steel wire armoured and lead
sheath PVC cable, earth plate, along with end of line resistor, with tag no. name plate,
design and manufacturing in conformity with NFPA-72 or BS5839 or EN.
Motor sirens shall also be installed as within new process and tankage areas to give
general audible warning to the plant people for abandonment and going to muster
stations or assembly points. This general alarm shall be operated at emergency plan by
authorized personnel. The restricted push button shall be located on front face of main
FGP in main control room and fire station.

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Since this project is an expansion project adding new facilities in the existing area,
additional motor sirens should be installed to the following area where the existing
sirens may not cover. The sirens shall be strategically installed so that their sound can
be heard anywhere in the plant. Approximate coverage of each siren should be
considered 600m radius area.
6.12
FGS Devices inside the Building
6.12.1 Manual Alarm Call Points (MCP)
Manual call point shall be conventional type, indoor installation, min. IP42/IP54
(indoor/outdoor), red epoxy color, glass reinforced polyester enclosure, exposed wall
mounted, break glass from plastic, suitable for ambient temperature -28 to 43 deg. C
and 73% relative humidity, reset by repositioning the element, terminals for 6X2.5 mm2,
switch ratings for 0-30 VDC, 5A resistive, cable entries 2 bottom entry M20, with cable
gland, earth plate, with tag no. name plate, design and manufacturing in conformity with
NFPA-72 or BS5839 or equal EN.
Every MCP should be located such that one need not cross/enter the hazardous area to
access the MCP. A MCP should not be placed where it can obstruct normal personnel
movement and cause unintentional alarm.
The MCP shall be located so that it should not take more than 30 meters to get to the
MCP in the building. The MCP shall also be provided in the plant building where people
are stationed, such as control room, substations, RIBs, etc.
Activation of MCPs shall activate an alarm annunciation in control room and in local.
Indoor MCPs shall be break glass and conventional type. The glass shall be held
depressed by the glass during normal conditions. The switch shall change over once
the glass is broken.
Alarm contacts shall be normally open in normal conditions and shall close when the
glass is broken. The alarm signal persists until the glass is replaced and the system is
reset.
6.12.2 Spot Heat Detectors
Heat detector shall be conventional & spot type, two types of rate of rise type and
fixed temperature, 75 deg. C temp. setting, fire LED and facilities for connection of
remote fire LED, 24 VDC power supply from fire alarm control panel, min. IP 42,
along with end of line resistor, complete with back box, mounting base, Junction box
and cable glands, with tag no. name plate design and manufacturing in conformity
with NFPA-72 or BS5839 or EN.
Rate-compensated, fixed temperature and conventional type detectors shall be used in
areas where quick temperature fluctuations are likely to occur during normal conditions.
However, the detectors function shall be limited to the initiation of alarms on maximum
air temperature. Such detectors shall not be used for a room with high ceiling (greater
than 7.5m), or where only smoldering fire can be expected. If quick warning is required,
they have to be associated with another temperature detector.
Heat detectors based on rate of rise principle including maximum temperature limit shall
be used for battery rooms and diesel generator rooms.
Where an executive action is required as a consequence of the detection of a fire,
detectors shall be used on 2ooN basis.

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The detectors shall incorporate a latching LED indication which when illuminated,
indicates the detector is in an alarm condition. This LED must remain illuminated until
The sensor head assembly shall be constructed such that the base may be installed
without the sensing element.
Detectors shall have plug-in capability and be suitable for flush/recessed and surface
mounting application.
6.12.3 Spot Smoke Detectors

Optical smoke detector shall be conventional and spot type, scattering operation, solid
state light emitting diode with associated lens system and photocell as receiving
device, fire LED and facilities for connection of remote fire LED, 24 VDC power
supply from fire alarm control panel, min. IP 42, along with end of line resistor,
complete with back box, mounting base, Junction box and cable glands, with tag no.
name plate design and manufacturing in conformity with NFPA-72 or BS5839 or EN.
The type of detector for Div.2, IIB, T3 shall be intrinsically safe EExib.
The optical and conventional type smoke detectors shall be used in areas where
smoldering type fires may occur as minimum.
Where detectors are to be installed under false floors or ceilings, remote indication shall
be provided.
Duct-mounted smoke detectors shall be installed on HVAC system ducts where
required.
Where an executive action is required as a consequence of the detection of a fire,
detectors shall be used on a 2ooN basis.
To prevent false alarm or malfunction caused by small insects entering the chamber,
detectors shall include fine gauze filters.
The detectors shall incorporate a latching LED indicating which, when illuminated,
indicates the detector is in an alarm condition. This LED must remain illuminated until
The sensor head assembly shall be constructed such that the base may be installed
without the sensing element. Response time shall be less than 5 seconds once the
smoke has entered the detector.
Detectors shall have plug in capability and be suitable for flush/recessed and surface
mounting application.
6.12.4 Beam Smoke Detectors
Optical beam smoke detector shall be conventional type, infra red beam, transmitter &
receiver modules, 24 VDC power supply from fire alarm control panel, detection range
0~ 100 meters, selectable sensitivity and alarm threshold, self check and automatic
compensation, low current consumption, suitable for ambient temperature -28 to 43
deg. C and 73% relative humidity, min. IP 42, alarm, trouble, and relay contacts, along
with end of line resistor, design and manufacturing in conformity with NFPA-72 or
BS5839 or EN.
The beam smoke detectors shall be conventional type and they work by transferring
the infra red beam by transmitter and receiving it by receiver module. They shall be fed
by 24 VDC power supply from fire alarm control panel. The detection range shall be 100
meters, with selectable sensitivity and alarm threshold, self check and automatic
compensation, low current consumption, alarm, trouble, and relay contacts. They are
ideal for using inside warehouses with high elevation.

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Page 30 of 42
6.12.5 Bells & Alarm Horns

Horns shall be conventional type, outdoor installation, min. IP54, red epoxy color, UV
resistance glass reinforced polyester enclosure. 24 VDC power supply from fire alarm
control panel, min. 130 db(A), suitable for ambient temperature -28 to 43 deg. C and
80% relative humidity, constructed for harsh environmental and corrosion resistance,
terminals for 6X4.0 mm2, cable entries 2 bottom entry M20, with back box, cable
gland, earth plate, along with end of line resistor, with tag no. name plate, design and
manufacturing in conformity with NFPA-72 or BS5839 or EN.
Each fire zone in buildings should have its own alarm bell that will warn the personnel
inside of the zone of a possible fire case.
It will be activated based on a 1ooN voting of detectors inside of the fire zone. It should
bell type and have a sound pressure range of 90 to 95 dB and suitable for indoor use
(IP-42).
Alarm sounders should be installed in corridors and out side of the buildings for warning
the personnel in a building. In case of fire in each fire zone inside of a building it will be
activated based on a 1ooN voting. It should have a minimum of 110dB sound pressure
and be weather proof for out side of the building installations.
6.12.6 Lighting Panels

Lighting fixture & lamp, indoor installation, min. IP42/IP54 (indoor/outdoor), power
supply 24 VDC, low consumption terminals for 4X2.5 mm2, cable entries 2 bottom
M20 & gland without internal battery backup, with sign label, cubicle shape, exposed
wall mounted. Explosion proof, EEXed, shall be considered suitable for Div1, G.B,T3.
Each protected zone with a gaseous extinguishing system shall be equipped with
lighting panels. NO ENTRY lighting panels should be installed outside of the zone
above each of the room doors and IMMEDIATE EXIT lighting panels should be
installed inside of the zone above each of the room doors.
They should be lighten after confirmation of the fire case in the zone (2ooN Voting of
zone detectors) to help the evacuation of the room and preventing the personnel from
entering the room before discharge of the gaseous extinguishing system.
They should have readable font and font style and suitable wattage of lighting. Also
Vendor should take good care about area classification of the zone especially for
battery rooms.
6.12.7 Manual Release Stations
Manual release station shall be double action with lift flap indoor installation, min.
IP42/IP54 (indoor/outdoor), exposed wall mounted ,red epoxy color, glass reinforced
polyester enclosure, break glass from plastic, suitable for ambient temperature -28 to 43
deg. C and 73% relative humidity, reset by repositioning the element, terminals for
6X2.5 mm2, switch ratings for 0-30 VDC, 5A resistive, cable entries 2 bottom entry M20,
with cable gland, earth plate, with tag no. name plate, design and manufacturing in
Manual release stations shall be provided at the entrance of the protected zones with
gaseous extinguishing systems.


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Page 31 of 42
6.12.8 Door Release Switch and Door Holder Magnet

Door release station, indoor installation, min. IP42, exposed wall mounted ,red epoxy
color, glass reinforced polyester enclosure, break glass from plastic, suitable for
ambient temperature -28 to 43 deg. C and 73% relative humidity, reset by repositioning
the element, terminals for 4X2.5 mm2, switch ratings for 0-30 VDC, 5A resistive, cable
entries 2 bottom entry M20, with cable gland, earth plate, with tag no. name plate,
design and manufacturing in conformity with NFPA-72 or BS5839 or equal EN.
Magnetic door holder, consist of two parts (wall mounted electromagnet and the
counter-plate fitted to the door), indoor installation, min. IP42, 24 VDC power supply
from fire alarm control panel, low current consumption, suitable for ambient temperature
-28 to 43 deg. C and 73% relative humidity, cable entries 2 bottom entry M20, with
cable gland, earth plate, with tag no. name plate, design and manufacturing in
Doors of the protected zones with gaseous extinguishing systems that are not blast
proof should be equipped with door holder switch and door holder magnets. Door holder
switches should be installed outside of the room.
Door holder magnet should be complete with required supports and accessories for
fixing on wall and door. Each door equipped with door holder magnet should have a
door closure mechanism.
In case of a confirmed fire in a protected zone, the related local FGS panel should send
a signal to all door holder magnets to release the room doors before start of the gas
release.
6.12.9 Alarm Sounders and Flash Lights
The specification is the same as alarm sounders and flash lights in the field except
ingress protection which for indoor installation should be considered as IP-42.
6.12.10Flammable Gas Detectors
The specification is the same as field gas detectors.
6.13
FGS Connection with Other Systems

Each extinguishing or other system shall be connected to the nearest FGP as per
configuration given in Overall Fire & Gas System Configuration Diagram #AK-00-90011/1 and also related block diagrams.
6.13.1 Deluge System for Fixed Water Spray Systems

Water deluge systems are provided for the equipment or group of equipment, which
handles flammable/combustible fluid. The deluge system consists of fire detection
devices and mechanical parts.
The automatic deluge systems will automatically be activated when relevant linear heat
detector (1ooN) or flame detectors (2oo2), detect a fire.
In addition, the manual deluge system will be activated by the remote hand switches
provided on the main FGP in the main control building or locally on the valve assembly.
Each deluge valve is equipped with following instruments:
Solenoid Valve for actuation of the Valve

High pressure switch on downstream of deluge valve for indicating the operation of
the valve

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Low Pressure switch on instrument air line for indicating the state of air pressure loss
on the valve trim
Hard-wired monitored signals of each deluge valve should be sent to local FGP in RIBs or
substations and repeated simultaneously to main FGP in main control building and FGPs
in new and existing fire stations through dedicated fiber optic network.
Remote manual activation of deluge valves should only be possible from main FGP in
rack room of MCR, while deluge valve status will be repeated to FGPs in new and
existing fire station. All status indications and push buttons for deluge valves shall be
arranged on front face of FGP in main control building.
6.13.2 Gaseous Extinguishing Systems
6.13.2.1 General Description of the System

These systems comprise from two different systems namely CO2 total flooding and
FM200 systems. The CO2 gaseous extinguishing systems shall be operated at three
modes of Automatic/Manual /Inhibit by a selector switch near the entrance of each
protected zone. At automatic position, system shall be automatically activated by
confirmed coincidence operation of fire detectors in the protected area. At this state the
system can also be triggered via manual release station available at the room entrance.
At manual position, system activation shall only be limited to manual release stations
allocated for this purpose. Manual activation on cylinder bank shall be non-electrical and
possible from cylinder area.
Inhibit position shall be used when an operator is going to enter a protected zone.
This selector switch shall be key operated intended to access only by authorized
personnel. Operators should be aware of the instructions of using this position, specially if
the agent is CO2 gas which could be harmful for the personnel.
A Main/Reserve switch should be available in the Gas Cylinder Room for putting the
system state at Reserve Cylinder Bank use if the main cylinder bank has been
discharged before.
A suitable mechanism such as weighing for CO2 system and pressure switch for FM200
system will be available to indicate that the gas cylinders are empty. In both systems
majority of mechanical and electrical hardware inside cylinder room such as high
pressure cylinders, cylinder racks, check valves, hose, pipe, tube & fittings, pipe support,
solenoid valve, weighing system, pneumatic operation directional valves, pressure or limit
switches, cable, conduit, tray, gland, elec. junction box and other required accessories is
excluded of F&G system Vendor.
6.13.2.2 Detection and Activation of the System
In fire zones that are protected with gaseous extinguishing systems, the fire detection
acts as cross-zone fire detection to minimize fault alarm risk. For these spaces, when a
single detector is activated, it shall initiate a pre alarm with following sequence:
Local alarm bell will be activated in the room
Lighting Panel IMMEDIATE EXIT light caution board located inside the protected
room will be lighten up to indicate that the room shall be evacuated (for rooms
accessible to people).
Smoke and motorized dampers on supply/return air ducts will be closed.
Pre-alarm Status indication and alarm in Local, Main Control Room, New and Existing
Fire Stations FGPs

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The actuation of the system shall be carried out after the second detector has been
activated and the agent will be released automatically with delay time of the 30 seconds.
The following sequences shall be carried out:
Initiate the same sequence as that described above. This sequence and that
previously described shall be characterized by distinct signalization (e.g. intermittent
light and sound for the first sequence, continuous light and sound for this sequence).
All HVAC units such as air handling unit, air packaged unit, and exhaust fan will be
shutdown.
Lighting Panel NO ENTRY light caution board located outside the protected room
will be lighten up to prevent people from entering the room where agent discharge is
nearly to happen.
Releasing the Door magnets for closing any intentionally opened doors if any.
After 30 sec. delay time command signal from local FGP will actuate the pilot cylinder
valve and agent of main cylinders will be discharged to the fired zone.
Gas Released Status indication and alarm in Local, Main Control Room, New and
Existing Fire Stations FGPs
Following Indications, switches and Status shall be available for gaseous extinguishing
systems:
Manual Release Station (one at entrance of each protected room, and mechanically
on cylinder bank)
Auto/Manual/Inhibit switch (one at entrance of each protected zone)
Auto/Manual/Inhibit status (on Local FGP and remotely on FGS console in Main
Control Room)
Normal Operation Status (for each protected zone on Local FGP and remotely on
FGS console in Main Control Room and common for all protected zones of a building
in existing and new fire stations FGS console)
Main / Reserve Switch (common for all protected zones at gas cylinder room)
Main / Reserve Status (Common for all protected zones on Local FGP and remotely
on FGS console in Main Control Room)
Fire Zone Status (For each protected zone on Local FGP and remotely on FGS
console in Main Control Room and common for all protected zones of a building in
existing and new fire stations FGS console)
Gas Released Status (For each protected zone on Local FGP and remotely on FGS
console in Main Control Room and common for all protected zones of a building in
existing and new fire stations FGS console)
System Fault including gas loss, wiring trouble (For each protected zone on Local
FGP and remotely on FGS console in Main Control Room and common for all
protected zones of a building in existing and new fire stations FGS console)
Silence Alarm Switch (common for all protected zones in a building on Local FGP and
remotely on FGS console in Main Control Room)
Reset Switch (common for all protected zones in a building on Local FGP and
remotely on FGS console in Main Control Room)


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6.13.3 Rim Seal Protection Systems

Pre-engineered clean agent system will be provided for rim seal protection of floating
roof tanks.
Rim seal protection system will be activated automatically by fusible plug type heat
detector on discharge ring.
Only signaling between rim seal protection system and FGP includes followings:
Low pressure switch on clean agent cylinder for indicating the pressure of expelling
gas
Low level switch on container for indicating the low level of extinguishing agent in the
agent cylinder
Hard-wired signals of each rim seal protection system should be sent to local FGP and
repeated simultaneously to main FGP in main control building and FGPs in new and
existing fire stations through dedicated fiber optic network.
6.13.4 Fire Water Supply System
On FGP in existing fire station two additional push buttons shall be considered for
start/stop of new fire water pumps.
7. FGS Design, Engineering & Procurement
The vendor shall perform all necessary detailed design, engineering, procurement of
materials, assembly, fabrication and testing of the FGS system. Moreover Vendor
shall execute system software configuration.
The Vendor shall prepare all specifications, drawings and other documents necessary
for the procurement, assembly, testing, installation, software configuration and
maintenance of the FGS system. The Vendor shall provide in the bid, the following
equipment details:
Voltage Tolerance
Frequency Tolerance
Max. Power Consumption
Heat Dissipation
The Vendor shall provide all system application software. The system shall consist of
the manufacturers standard hardware, system software and firmware that can be
configured to meet the stated requirements. Equipment provided as part of the
system shall be filed proven prior to placement of the order. Field proven is defined
as successful operation of a standard product at a field installation of 3 years or more.
The Vendor is to specify in the bid, the authority which released the PLC certification.
The Vendor shall furnish all equipment, material and tools for the installation,
operation and maintenance of the FGS system together with spare parts sufficient to
cover any normal damage during testing, installation, start-up and commissioning.
The Vendor shall prepare all non-standard drawings.
The Vendor shall propose his standard procedure for packing, marking and shipping
of the equipment to be reviewed by the Purchaser and mutually agreed upon in due
time.

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The Vendor shall provide the necessary project administration and key personnel.
The Vendor shall provide automatic notifications and copies of all software updates.
The Vendor shall provide an on-line bulletin board service to stay current on all
system enhancements and contact other users.
8. Inspections and Tests

During the fabrication period the materials and production documents shall be subject to
inspection by the Purchaser inspectors.
Inspection may also regard all accessory materials.
The Vendor shall allow free access to the Purchasers inspectors to its factories and supply
all information requested as well as make available all copies of internal orders to subsuppliers.
8.1
Tests
8.1.1
Scope
This section describes the requirements for testing of the FGS system.
The following level of tests shall be carried out:
Level 1 test: on individual components
Level 2 test: on integrated system
Level 3 test: on system loaded with project configuration
8.1.2
Deviations
The Vendor shall indicate in the bid offer any deviation and/or exception from these test
requirements.
The lack of any deviation and/or exception will be considered as full compliance with
specifications.
8.1.3
Documentation
The system will be tested in compliance with the following documentation:
8.1.4
This document
Project Specifications
Application software documentation
System drawings
Functional design specification
Vendor Test procedure
Test Methodology
Factory Acceptance Test FAT shall be performed in the factories of the manufacturer at
this care expense, and after completion of all above mentioned tests, the Purchasers
inspector will witness the FAT and Vendor shall notify the Purchaser of the scheduled


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dates 4 weeks prior to actual test as preliminary notice and 15 days prior to actual test as
firm notice.
In the case the Purchaser waives to witness the FAT in writing, the Vendor shall provide
the relevant test certificates with all test results.
Actual configuration specified for the project shall be loaded, thus verifying that within a
reasonable degree of confidence, the control system will perform exactly as per specified
both from hardware and software point of view.
In this situation, before commencement of the functional tests it will be necessary to
ensure that all the contract documentation is present and all relevant Vendor drawings
are approved by the Purchaser as Final Drawings. In case the Purchasers inspector
waives to witness the test, the manufacturer shall issue certificates of the carried out
tests, with all necessary information and the result of the measurements.
In any case, the Vendor shall state in his proposal the grade of compliance of his
procedure and the aforesaid ISA recommended practice.
Test procedure approach will involve a sequence of layered of checks, starting from
simple subsystem tests to complete control/logic strategies verification.
It is the totality of this series of tests which is intended to establish confidence that the
FGS system will perform its specified functions correctly and reliably.
Functional tests fall broadly into three main categories:
A. Functional tests on all standard system software/hardware characteristics (i.e. system
diagnostics, fault handling, redundancy operation, etc.)
B. Functional test on input and output channels
C. Operational tests of the logic and/or analogue control, as implemented in the system
configuration.
FAT checks will be performed following manufacturer standard procedure for point A.
Point B shall be performed on 100% I/O basis, unless stated differently by the Purchaser.
Point C shall be performed after positive completion of above points A and B.
During the FAT, the following tests shall be carried out as a minimum:
A. Visual Inspection:
Verifying that all parts/components specified are present

Check that all instruments/equipment is properly identified with adequate tag plates
Check that all documents have been supplied and are consistent with the instruments
under test
Dimensions checked as per relevant drawings
B. Performance Test:
Functional Checks as per the FAT requirements
1) Factory Acceptance Time table

The test will be conducted in accordance with a time-table that will be agreed between
control system Vendor and the Purchaser.
2) Unscheduled Time

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Unscheduled time will be available during the FAT in order to permit the solving of any
problem without affecting overall test duration.
3) Failures
In the event of a failure of a device under test to operate correctly, due to hardware fault,
a substitute device will be tested. If the faulty item can be repaired, it will be demonstrated
later in the FAT.
A failure rate which exceeds 5% of the quantity of the unit-type concerned will require all
units of that type to be tested. However, this requirement will not apply to consoles or any
other devices that make up less than 20 units of the extent of supply.
Incorrect operation arising from an error in the system or software configuration will be
rectified as soon as possible and demonstrated either later in the FAT or punch listed and
tested at an agreed later date.
4) Acceptance Certificate
On the successful conclusion of the FAT, an acceptance certificate will be signed by the
Purchasers inspector.
5) Final System Acceptance
Installation and Checkout Plan
The vendor shall prepare an Installation and Checkout Plan that details the plans and
procedures to be followed during the installation and checkout of the system at the
installation site.
The objective of the Site Acceptance Test (SAT) is to demonstrate the total FGS
meets all requirements of the technical specification after the system is installed in
field and before the connection of the field equipment.
The SAT plan and procedure shall be used as the basis for monitoring the
performance of the SAT and for determining satisfactory completion of the SAT. The
SAT plan and procedure may be essentially a copy of the FAT pan and procedure,
the only difference is that the factory un-testable items shall be tested and the SAT
plan and procedures shall address the testing of these items.
After signing of the system installation certificated, the Purchaser shall perform the
SAT according to the approved SAT plan and procedures with Vendor personnel in
attendance. The SAT plan and procedure used shall be those confirming to the
technical specification. The Purchasers representative shall have pass/fail approval
authority on the SAT. Approval shall be based solely on the results of the SAT.
The SAT shall be conducted in the same manner as the FAT. The SAT report shall
be responsibility of the Vendor and the format shall be the same as that specified for
the FAT report.
The SAT shall be considered complete upon the satisfactory performance of all tests
required under the SAT plan and procedures, resolution of all discrepancies and
updates of the documentation.

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Operational Availability Test (OAT)
Prior to the planned start-up, the operational availability test (OAT) shall be
conducted upon the completion of the SAT and the connection of all field instruments
to the system.
The OAT shall be performed to demonstrate the reliability of the system once it is in
operation at the work site. The duration of the OT shall be for thirty (30) consecutive
calendar days. A full functional test of the system will live external devices and other
systems shall be carried out. The full requirement of the test will be defined in the
Site Acceptance test Procedure.
Final System Acceptance

The Purchasers representative shall provide a written confirmation to the Vendor Final
Acceptance upon satisfaction of the followings:

Operational Availability Test
Final updates to any deliverable drawings and documentation as required to
accurately reflecting the as-built system completion of the SAT
Resolution of identified discrepancies an a punch list
9. Training
The Vendor shall provide detailed information of factory and onsite training of the
personnel and typical equipment required t provide the training.
The cost of training shall be quoted separately.
Updates and exact training costs are required at least six (6) months before delivery of the
system.
10. Planning & Time Schedule

Schedules shall be mutually agreed upon as necessary during the technical negotiations
for the supply. The total project shall be divided into a listing of main sections.
These main sections shall be further subdivided into basic project activities. The split shall
be made by dividing the main sections between the participating project
members/departments.
For each basic activity the following items shall be estimated:
Earliest start date

Latest start date
Duration
Earliest finish date
Latest finish date
An overall plan in bar-chart format shall be established. The bar chart plan shall indicate
the progress made to date. The progress shall be indicated at regular intervals (on a biweekly weekly basis), unless circumstances dictate a more frequent update.

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 39 of 42
The schedule shall be used as a basis for progress reporting, schedule controlling and
schedule forecasting.
The submission, updating, change or revision of any schedule or any report by the Vendor
shall have the effect of amending or modifying the required milestone completion dates
without prior to Purchaser written approval issued by the Purchaser and signed by the
Vendor.
11. Deviations & Alterations

Any omission of detail in this specification shall not relieve the Vendor of his obligation to
furnish complete functional equipment with reliable and satisfactory operation.
In principle, deviation from the Purchasers applicable documents, other than those
proposed by the Vendor as an important scheme, will not be accepted.
The Vendor agrees that the only deviations and alteration to be considered by the
Purchaser shall be limited to those separately specified in the proposed deviation list
accompanying the Vendors proposal and that the Purchaser has no responsibility to
discover any deviations or alterations, entered in other parts of the proposal. If the offer is
awarded, it must comply with the applicable documents as revised only to reflect the
deviations and alterations listed and accepted by the Purchaser.
Should any conflict arise among the requirements of these specifications, standards and
the Vendors proposal, the following order of precedence shall govern:
Purchase Order (PO)

This specification
Other applicable standards referred to in the specification 4. Other recognized
international standards and codes
In case of conflict between any of the above documents, the Vendor shall bring the matter
to the Purchaser's attention. The VENDOR shall outline the conflict, the implication for the
conflict and suggested resolution of conflict. Once the conflict has been brought to the
attention of the Purchaser, the Vendor shall proceed on the basis of the order of
precedence outlined herein unless otherwise instructed by the Purchaser.
The Vendor shall clearly describe his specification item versus the Purchaser's
specification in his technical proposal.
As a minimum, the following comments shall be clearly defined:
A: Acceptable: When the Vendor's proposal meets the Purchaser's specification without
any deviation or clarification.
B. Deviation: When the Vendor's proposal has a deviation. The Vendor shall clearly
indicate the reason, and prepare an alternative proposal. The Vendor may suggest
improvements based on their experience, if any.
C. Clarification: When the Vendor's proposal has a clarification. The Vendor shall indicate
the clarification.
Failure to comply with the above requirements will disqualify Vendor summarily.


Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 40 of 42
12. Documentation
12.1
Supply of documents
The Vendor shall provide, with the application program and FGS configuration, the
following material but not limited to:
A listing of the I/O configuration identifying each module, location and tag
Printout of all programs in ladder logic format
An index of the system's data base including tag names, descriptions and initial
values
A complete narrative describing the operation as sequence of the logic and control
system.
A fault finding/trouble shooting narrative for the complete FGS. Recommended format
is an "if-then" condition diagram.
Installation, operation and maintenance/trouble shooting manuals. .
Engineering documents containing but not limited to:
Assembly and interconnecting wiring diagrams
Interface details between Sub-Systems
Input/output termination
Power distribution block diagrams
I/O module indexes
Cabinet arrangement drawings
Two wire diagrams for all signal points acquired by the FGS (Loop Drawings)
Datasheets of devices / equipment
Programming manuals
Calculation of the overall FGS availability/reliability including the failure mode and
effect analysis
Recommended spare parts list and pricing
List of Sub-Vendors & data sheets
Grounding system: The Vendor shall prepare the relative study and detail
engineering in accordance with current international standards
Generic or standards documents with no specific reference to the supply, shall not
be accepted
Within 8 weeks of order placement, the Vendor shall provide for the Purchaser's approval
the Functional Design Specification (FDS). The FDS shall represent the Vendor's
interpretation of the Purchase Order specification in detail to enable the Purchaser to verify
that the system design meets the requirements of the Project. A detailed planning network
is to be produced showing all FDS shall include and contain, as a minimum:
System hardware, broken down to each type of unit
Interface details
I/O allocations (on unit basis)
Configuration details
Graphic display details
Data link development, software production and testing. Document issue dates
Data format tables and protocols
Performance
Availability/Reliability analysis

Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 41 of 42
Test plan
Test requirements
System constraints and limitations
System topology
Project Management
Organization
Critical Path Analysis
Quality Control/Assurance, Test Plan
The Vendor shall carry responsibility for the accuracy of the Vendor's documents furnished
to the Purchaser.
The Vendor shall indemnify the Purchaser against any damage or loss suffered by the
Purchaser, as a result of any defect in the Vendor's documents attributed to the Vendor.
In the event that any defect in the Vendor's documents attributable to the Vendor result in
correction of construction and erection work of the equipment, performed or to be
performed by the Purchaser, the additional cost associated with such correction shall be
born by the Vendor.
13. Exclusion
-
Following items are excluded from supply of Fire & Gas system Vendor:
Fire & Gas Console within Control Room.
One LCD monitor, 19, antiglare, low radiation, non-capacitive, minimum 16 distinct colors
fixed on console.
Industrial Grade Keyboard, spill or dust proof membrane.
14. Spare Parts

The Vendor shall state his policy against system hardware enhancements or upgrading i.e.
hardware replacement with special prices or discount. In the belief that portions of the
system will eventually be withdrawn from sale, a firm commitment shall be taken by the
Vendor that for the standard products there will either be repair capability or equivalent
parts and/or products available for a minimum of ten years from withdraw able date. The
Vendor shall guarantee that spare parts for any component or module shall be available for
a period of at least 2 years operation.
The Vendor shall also indicate the location of his nearest technical and service offices.
The Vendor shall quote in a priced list, commissioning spare parts for items, which, in his
experience has shown can be easily lost (i.e. fuses, I/O modules, etc.).
The Vendor shall recommend spares for items that have a limited life expectancy over a
two-year time period. The list shall be priced.


Upgrading Project
Job Specification
For
Fire and Gas System
PMO
Document No.
SP-2260-90-421-3
NIOEC
Project No : 2260
Rev.
03
Page 42 of 42
15. Special Tools
The Vendor shall inform and provide the required special tools for commissioning, start
up, test and operation of system. The complete list along with unit price shall be submitted
for necessary accessories for programming, calibration and test tools for F&G system at
Vendors quotation at proposal stage.


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Shazand Arak Refinery Expansion and

File Ref. : T:\Issued Documents to Employer\Engineering Directorate\FA\SP-2260-90421-3\SP-2260-90-421-3.doc

Revised as Indicated as per NIOEC Comments

Revised as Indicated as per NIOEC Comments

Revised as Indicated as per NIOEC Comments

Issued for Approval

This Document belongs to NIOEC and is confidential.

Shazand Arak Refinery Expansion and

Codes and Standards ................................................................................................... 5

Definitions and Abbreviations .....................................................................................7

General Requirements ...............................................................................................8

File Ref. : T:\Issued Documents to Employer\Engineering Directorate\FA\SP-2260-90421-3\SP-2260-90-421-3.doc

Environmental Conditions ............................................................................................. 8

FGS Design, Engineering & Procurement ...............................................................34

Inspections and Tests ..............................................................................................35

Planning & Time Schedule ...................................................................................38

Deviations & Alterations........................................................................................39

Supply of documents .................................................................................................. 40

Shazand Arak Refinery Expansion and

Spare Parts ...........................................................................................................41

Special Tools ........................................................................................................42

File Ref. : T:\Issued Documents to Employer\Engineering Directorate\FA\SP-2260-90421-3\SP-2260-90-421-3.doc

This Document belongs to NIOEC and is confidential.

Shazand Arak Refinery Expansion and

File Ref. : T:\Issued Documents to Employer\Engineering Directorate\FA\SP-2260-90421-3\SP-2260-90-421-3.doc

Shazand Arak Refinery Expansion and

Language and Units

Codes and Standards

File Ref. : T:\Issued Documents to Employer\Engineering Directorate\FA\SP-2260-90421-3\SP-2260-90-421-3.doc

(BRITISH APPROVALS SERVICE FOR ELECTRICAL

(BRITISH STANDARDS INSTITUTES)

(EUROPEAN COMMITTEE FOR STANDARDIZATION)

(ELECTRONIC INDUSTRIES ASSOCIATION)

(INTERNATIONAL ELECTROTECHNICAL COMMISSION)

Shazand Arak Refinery Expansion and

Tests for Electric Cables Under Fire Conditions - Circuit Integrity

(NATIONAL FIRE PROTECTION ASSOCIATION)

AMERICAN PETROLEUM INSTITUTE

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This Document belongs to NIOEC and is confidential.

Shazand Arak Refinery Expansion and

3. Definitions and Abbreviations

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One out of One

This Document belongs to NIOEC and is confidential.

Shazand Arak Refinery Expansion and

Hazardous Area Classification and Ingress Protection

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Primary Power Supply

Shazand Arak Refinery Expansion and

Secondary Power Supply

File Ref. : T:\Issued Documents to Employer\Engineering Directorate\FA\SP-2260-90421-3\SP-2260-90-421-3.doc

5.4.1.1 Signal Cables

Outdoor Above Ground Application

Shazand Arak Refinery Expansion and

5.4.2.1 Signal Cables

Outdoor Buried Application

5.4.3.1 Signal Cables

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Noise Immunity (RFI/EMI)

Reliability of Fire & Gas System

Shazand Arak Refinery Expansion and