Case study of an upgrade for the replacement of a Fire & Gas system at an Oil Pumping station.

The challenge

The Fire & Gas Detection System equipment was partly installed approximately 15 years ago during the Iraq conflict and was not fully commissioned. The Fire & Gas Detection system was not fully functional and the turbine units were not being protected as designed.

The customer wanted to replace their current common Fire & Gas Detection Panel that was supposed to monitor the three (3) Dresser Rand Turbine Pump Sets, along with three (3) sets of package Fire & Gas Field devices, junction boxes and associated field cabling.

The new Fire & Gas Detection Panel was to be located in the Pump Station Central Control Room located approximately 250 meters away from the turbine packages and had to interface to the customer's existing package suppression system.

The customer was primarily interested in replacing the equipment due to functionality, component obsolescence and supportability. We were requested to engineer a new design that satisfied the special site specific requirements and that could be easily be expanded upon in the near future if required. 

Our solution

To design, build and test a replacement Fire & Gas Detection Panel having similar functionality as the original panel, but using the latest available components and methodologies.

Our designed solution was slightly different to the original in that the Fire & Gas Detection Panel that was to be located in the Central Control Room was not common, but was designed and constructed to consist of three independent Fire & Gas Detection systems assembled in one panel. This allowed the customer to have the flexibility to isolate and depower if required for maintenance and support a single package independently along with its Fire & Gas Detection system without impacting the safety & operation of the other two running turbine units.

Scope

  • Provision of three New Fire & Detection systems in a Common Panel, Fire & Gas Detection Field Devices and Junction Boxes.
  • Provision of a comprehensive Fire & Gas ‘Cause & Effect’ matrix.
  • Provision of Fire & Gas System Drawings in AutoCAD format.
  • Provision of test procedure and point to point wiring schedules.
  • FAT Testing of the three independent Fire & Gas Detection Systems & field Devices.

Before

After

Conclusion

Our attention to detail, practical and pragmatic approach has given our customer a modern, flexible, expandable and maintainable solution correcting many of the faults and provided enhancements to the original design, thus ensuring the replacement Fire & Gas Detection panel will provide reliable functionality for years to come.