Document No.

30-A-083
Applicability All INEOS companies
operating at or associated
with the Grangemouth Site
Date 15 March 2011

Standard for
Fire and Gas Detection Maintenance

SITE STANDARD
15 March 2011 30-A-083
Issue No.1.0 Standard for Fire and Gas Detection Maintenance

Foreword

This is the first issue of Site Standard 30-A-083. This standard replaces the following
heritage documents.

Superseded Documents

GEMS 30-006 Maintenance of Fire and Gas Detection Systems

Heritage documents are archived and can only be made available for reference purposes
with agreement from the Technical Authority.

Change Record

Author Issue Review Description of Change Comms to Comms

Date Method
N Waller 1.0 15/3/2011 First issue Leadership Engagement
process
J Wilson 1.1 21/5/2012 Removal of IMSL references (SP- Site Monthly Update
085)

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Issue No.1.0 Standard for Fire and Gas Detection Maintenance

Table of Contents

Page
Foreword............................................................................................................................................2
Introduction.........................................................................................................................................4
1. Scope........................................................................................................................................5
2. Normative references................................................................................................................5
3. Terms and Definitions...............................................................................................................6
4. Symbols and abbreviations.......................................................................................................6
5. General.....................................................................................................................................6
5.1 Legislative regulations, local codes, and standards......................................................6
5.2 Safety management.......................................................................................................6
6. Operation and Maintenance:.....................................................................................................7
6.1 Routine Inspection and Testing. 7
6.1.1 Fire & Gas Detection / Alarm Panels…………………………………...…………………….8
6.1.2 Detection & Alarm Equipment………………………………………………………………..8
6.1.3 Suppression Equipment………………………………………………………………………9

Appendices

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Issue No.1.0 Standard for Fire and Gas Detection Maintenance

Introduction

Fire & Gas Protection Systems play a key role in the mitigation of risk associated with the
flammable and toxic materials handled on site. They are also used for protection in areas
such as office buildings, substations, canteens etc. To ensure that these systems remain
fit for purpose, periodic maintenance must be preformed and documented in a controlled
manner.

Fire and Gas (F&G) or Fire and Gas Systems are terms used to describe groups of fire and
gas detection instruments with individual detectors connected to either area wide or a
series of local control panels. These usually cover specific areas in process plant or
buildings with diagnostic information and controlling logic derived within these panels.

The maintenance of these systems should take account of their expected measurement
performance criteria, areas of coverage, interfaces to Fire Alarms, Sitewide alarms, or
DCS.

Due to the large numbers of individual detectors, diverse selection of systems, and the
large geographical spread of equipment a systematic approach is needed in order to
ensure that the installations remain reliable with reasonable levels of maintenance support
and usage of consumable spares/ materials.

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1. Scope
This Standard covers the maintenance of fire and gas systems on INEOS sites. Equipment
is located in process plant areas (field equipment) and within offices and plant buildings.
These buildings can be located inside and outside the designated process plant areas.

This Standard covers work to be done by Ineos Technicians or specialist Contractors

whether initiated by planned maintenance, ad hoc requests, or service contract shedules.

2. Normative References
The following normative documents contain requirements that, through reference in this
text, constitute requirements of this standard. For dated references, subsequent
amendments to, or revisions of, any of these publications do not apply. However, parties to
agreements based on this technical practice are encouraged to investigate the possibility
of applying the most recent editions of the normative documents indicated below. For
undated references, the latest edition of the normative document referred to applies.

INEOS Manufacturing Scotland Ltd Documents

GMP 27-2 Management of Fire and Gas Detection Systems

GMP 21 Management of Safety Instrumented Systems

GMP 22 Flammable Hazardous Areas

Standard 30-A-081 Fire and Gas Detection System Design

Standard 30-A-082 Fire and Gas Detection Equipment Selection

BS/ IEC International Electrotechnical Commission

BS EN 54-1 Fire Detection and Fire Alarm Systems Part 1: Introduction -

Supersedes BS 5445: Part 1: 1977

BS EN 5839-1 Fire Detection and Alarm Systems for Buildings

BS EN 50073 Guide for Selection, Installation, Use and Maintenance of Apparatus

for the Detection and Measurement of Combustible Gases or Oxygen
- CORR 13167: June 2001; Supersedes BS 6959:1989;

BS EN 61779 (parts 1-5) Electrical apparatus for the detection and measurement of
flammable gases — Part 1: General requirements and test methods -
AMD 15396: October 29, 2004

BS 5306-4 Fire extinguishing installations & equipment on premises.

Specification for carbon dioxide systems

BS 5430 Periodic inspection, testing and maintenance of transportable gas

containers

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3. Terms and Definitions

For the purposes of this Standard, the following terms and definitions apply:

xxxxxxxxxxx

4. Symbols and abbreviations

For the purpose of this standard, the following symbols and abbreviations apply:

yyyyyyyy

5. General
5.1 Legislative regulations, local codes, and standards
If Fire and Gas legislative requirements for an area conflict with guidance given in this
Standard, legislative requirements shall take precedence.

Fire and Gas equipment shall be maintained in order to comply with relevant local/ national
codes and standards.

Any changes to the maintenance regime that would effect the performance requirements of
the system should include the input from the following:

Risk assessors.
Safety teams.
Maintenance teams.
Technical support teams.
Process Operation Teams

5.2 Safety management

If any of the Fire and Gas detection systems are assessed at integrity level SIL 1, EIL 1 or
higher, the requirements of GMP 21, the Management of Safety Instrumented Systems,
and its associated standards shall be applied.

If any parts of the Fire and Gas detection systems are located in flammable hazardous
areas the requirements of GMP 22, the Management of Flammable Hazardous Areas, and
its associated standards shall be applied.

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6. Operation and Maintenance

The accountability for maintenance is defined in GMP 27-2 Management of Fire and Gas
Detection Systems.

6.1 Routine Inspection and Testing

Detectors may be grouped by geographical location and allocated a work pack/task
number within the maintenance management system (MMS). If the MMS utilises the
“Route” function this should be used to implement this type of maintenance. A master
Work Order is generated to cover multiple tags thereby simplifying the administration of a
large number of devices whilst still allowing the details to be recorded down to the device
level. Corrective work orders shall be raised against individual defective devices to allow
the master Work Order to be closed out and accurate maintenance compliance reported.

In order to build up a maintenance record for each item of equipment, the “Failure
Reporting” section of each Work-Order shall be completed prior to the Work-Order being
closed. As a minimum, the standard “Failure Class” categories shall be completed (e.g.
“No fault Found” etc.) Additionally, if any adjustments were found to be necessary or a fault
was identified, the “Long Description” (free text) field should be used to record the relevant
details.

The data shall be available from the MMS to support the production of regular reports on
equipment availability in order to confirm that the system is performing satisfactorily.

The information recorded on the test sheets shall form the basis for a periodic review of
operating/maintenance history.

6.1.1 Fire & Gas Detection / Alarm Panels

Each panel will be tested to ensure the correct functional operation of the system in line
with the manufacturers’ instructions and latest revision of cause and effect matrices or
functional design specification.

Panel function testing will be carried out in conjunction with the checks on the system
detection and alarm equipment, therefore simulating realistic alarm conditions.

As a minimum, each logic path through the panel should be verified e.g. for each fire zone
sufficient devices should be triggered to activate the relevant output.

Application of appropriate override/inhibits will be required to prevent executive action/false

alarms. Appropriate authority to apply these overrides shall be recorded.

It is not intended that every combination of input voting should be tested during these
checks however a record should be kept of the devices used to activate the output and
different devices be used for each test so that over a number of tests all combinations of
inputs are exercised.

As well as simulating alarm conditions on the panel it is also required to simulate system
fault conditions to prove control panel/system fault monitoring loops, where applicable.

The test of links to external alarm and other systems shall also be recorded.

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6.1.2 Detection & Alarm Equipment

Detection & Alarm devices shall be inspected and tested for correct operation, sensitivity
and calibration in accordance with the manufacturers’ instructions. All field devices shall
also be checked visually to confirm that there is no significant deterioration in the general
condition of the unit and its associated connection boxes and wiring.

Suitable test medium / equipment shall be used for the functional testing, in accordance
with manufacturers’ recommendations. Valid calibration certificates shall accompany all
test medium/equipment.

The following test periods are recommended:

Table 1.

Equipment Test Period

Alarm Panel / System 3 Months
Smoke Detectors 12 Months
Aspirating Smoke Detectors 12 Months
( inc VESDA):
Heat Detectors 12 Months
Flame Detectors 12 Months
Gas Detectors (Pellistor): 3 Months
Gas Detectors (Optical): Depends on detector
internal diagnostic
capabilities – refer to
manufacturers’
recommendations.
Miscellaneous Field Inputs: 6 Months
i.e. Status/Limit Switches
etc
Manual Call Points 12 Months
System Outputs 6 Months
Alarm Sounders & 3 Months
Indicating Lights:

The test periods in table 1 are based on normal industry practice. Alternative periods may
be defined by the manufacturer in their maintenance documentation. For testing which
does not follow these guidelines, or where none is available, Asset Owners should adopt a
risk based approach to determine maintenance periods utilising the device criticality and
failure rate to determine optimal intervals.

Process area systems

There are a large variety of systems across the INEOS sites with individual requirements
depending upon the processes concerned and the design philosophies applied at the time
the systems were installed. Maintenance frequencies will be defined by the Asset Fire and
Gas System owner and recorded as part the asset care policy for each plant.
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Buildings and other non process area systems.

The Asset Owner and Maintainer shall work together to ensure that when developing the
maintenance program the devices are distributed to ensure that at least one unit on each
detection zone will be operated every 3 months, therefore proving every panel zone during
the system 3 monthly tests.

The maintenance program shall be implemented such that approximately a quarter of the
12 monthly tested devices and half of the six monthly tested devices shall be inspected
and tested for each system, in conjunction with the system Fire and Gas Detection/Alarm
panel 3 monthly test. This is to ensure that any common mode failures do not remain
undetected for the full maintenance interval.

6.1.3 Suppression Equipment

For CO2 systems, the container contents shall be verified, the functionality of the firing
mechanism tested, operation of associated alarms checked and the condition of discharge
piping/system hoses verified, all on a six monthly frequency.

The requirements of BS 5430 Periodic inspection, testing and maintenance of

transportable gas containers shall be applied.

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