 Q : What Is fire and gas system

Ans :The Fire & Gas system in any plant is a “Safety System” in order to safeguard the
personnel and plant and Equipment. The system protects personnel from toxic gases as
well as possible fire hazard. The system protects the plant from possible fire and
consequent damage.

The system provides alarms in the event of potential hazard from toxic environment or
fire hazard. Further the system shuts down plants in the event of impending disaster
such as possible Fire (due to high level of combustible gases). The system is always
associated with control actions such as Trip of devices / plants.

 Q :Explain Ingress protection (IP)

Ans :INGRESS PROTECTION (IP) CODES

The IP code consists of 2 digits XY. The first numeral X stands for
protection against solid bodies and the second numeral Y stands for protection against liquid
bodies. This IP code is intended for electronic enclosures, junction boxes, panels and so on.
Example: IP65 stands for equipment is dust-tight and protected against water jets.

IP66 stands for equipment is dust-tight and protected Heavy seas

IP67 stands for equipment is dust-tight and protected Effect of immersion

IP55 stands for equipment is Dust protected and protected Water jets

 Q : How much and explain calibration Methane gas mixture

Ans :
The LEL of Methane is 5% of gas in air. Now Combustible Gas detectors are calibrated in
terms of %of LEL i.e. 0 to 100% LEL. ANY COMBUSTIBLE GAS CAN BE IGNITED
ONLY AT 100% LEL BELOW 100% LEL THE GAS CANNOT BE IGNITED AS
EXPLAINED ABOVE.
5% of Methane in air i.e. 5 units of Methane and 95 units of air in a mixture of 100 units form
LEL for Methane (for other gases Ethane, propane and so on the LEL may be different).

Test Gases are used to calibrate Combustible Gas Detectors (0 to 100% LEL). 5% of Methane
forms 100% LEL, if a test gas is marked (on the outside of the test cylinder) 2.5% of Methane by
Volume it forms 50% LEL, similarly if a test gas is marked (on the outside of the test
cylinder) 2% of Methane by Volume it forms 40% LEL.
  Q :Explain working principle of flame(UVIR) detector

Ans :The model FL-3101 is a flame detector which contains an ultraviolet uv photo tube which
responds to uv radiation in the 185 to 260nm region. When radiation from a flame reaches the
cathode plate within the uv detector tube, electrons are ejected from the cathode plate. These
electrons are accelerated towards the positively charged anode of the tube. They collide with
molecules of an ionzable gas, with which tube is filled. This emits more electrons and produces
an avalanche condition. More electrons are released which creates a momentary electron flow
from the cathode to the anode. This momentary current(pulse) recurs at a rate proportional to
the intensity of the uv radiation.

 Q : Explain working principle of h2s detector

Ans :General monitors uses a proprietary metal oxide semiconductor(MOS)
Film on the sensor for detecting H2S.The MOS film is deposited on to a
Subtract between two electrodes. With no gas present, the measured resistance
Between these two electrodes is very high(Mega ohms). As an H2S adsorbs on to
The film the resistance between the two electrodes decreases( to Kohms). This decrees
In resistance is logarithmically proportional to the concentration of H2S that is present.
The change in resistance is converted to a change in voltage, and amplified by the
input Circuit. This amplified signal is fed to an Analog to Digital converter, converted to
a digitalSignal and send to a microprocessor to be processed. The process of H2S
absorbing on to the MOS film is most effective at an elevated temp. On the outer edge of
the substrate is a heater Ring. The temp of this heater ring is measured with a
thermistor, and kept constant by a circuitLocate inside the body of the sensor. As H2S
absorbs on to the film, electrons move more freely from one electrode to the other/This is
represented as a decrease in resistance. The process of H2S absorbing on to the MOS
Film is completely reversible. As the concentration of H2S decreases (H2S desorbs), the
resistance Between the electrodes will increase.
 Q :Explain working principle of Smoke detector (ionization and optical
types)

Ans :IONISATION SMOKE DETECTOR

The sensing part of the detector consists of two chambers- an open, outer chamber and a semi
sealed reference chamber within. Mounted in the reference chamber is a low activity radioactive
foil of americium 241 which enables current to flow between the inner and outer chambers
when detector is powered up.
 As smoke enters the detector, it causes a reduction of the current flow in the outer chamber
and hence an increase in the voltage measured at the junction between the two chambers. The
voltage is monitored by the electronic circuitry which triggers the detector into the alarm state
at a preset threshold. An externally visible led will light up when the detector changes to alarm
state.

An integrating ionization detector suitable for using areas where transient high levels of
smoke may be expected is also available.

OPTICAL SMOKE DETECTOR:

Optical smoke detector incorporate a pulsing led located in a labyrinth with in the housing of
the detector. The labyrinth is designed to exclude light from any external source. At an angle to
the led is a photo diode which normally does not register the column of light emitted by the led.

In the event of smoke from a fire entering the labyrinth the light pulse from the led will be
scattered and hence registered by the photo diode. If the photo diode “sees” smoke on the two
following pulses, the detector changes to the alarm state when the indicator led will light up.

The detector housing is identical to that of the ionization smoke detector. It is distinguished
from this type by having an indicator led which is clear in quiescent state but produces red light
in alarm.

The optical detectors are easy to disassemble and clean without the necessity of returning
them to the factory.

 Q :Explain working principle of bimetallic type heat detector

Ans: Bimetallic

When two metals having different coefficients of thermal expansionare bonded together and
then heated, differential expansion causes bending or flexing toward the metal having the lower
expansion rate. This action closes a normally open circuit. The low expansion metal commonly
used is invar, an alloy of 36% nickel and 64% iron. Several alloys of manganese-copper-nickel,
nickel-chromium-iron, or stainless steel may be used for the high expansion component of a
bi-metal assembly. Bi-metals are used for the operating elements of a variety of fixed
temperature detectors. These detectors are generally of two types- bi-metal strip and bi-metal
snap disc. Devices using a bi-metal strip operate as follow: As strip is heated, it deforms in the
direction of the contact point. With a given bi-metal, the width of the gap between the contacts
determines the operating temperature. The wider the gap, the higher the operating point

 Q :Explain differ between ESD system and F & G system

Ans: For an ESD, a process upset will in a process shutdown .ESD systems are
preventative layers of protection, meaning that they act to prevent hazardous event like
a chemical release, fire, or explosion from occurring.
 A FGS is a mitigating layer of protection because the purpose is to reduce the
consequence severity of such an event when it occurs. When a combustible gas, a
toxic gas, smoke, flame, or heat is detected, then the FGS will respond by
annunciating audible and visual alarms and initiate a water deluge, fire
suppression system, or a process shutdown. In the event of a gas leak, the FGS
can act to prevent it from becoming a fire or explosion by isolating the leak and
ignition sources.

 Q :Explain Deluge system

Ans:A Deluge System is a fixed fire protection system in which the pipe system
is empty until the deluge valve operates to distribute pressurized water from
open nozzles or sprinklers

 Q :Draw 2 out of 3 ladder logic

Ans :

If any 2 input high out also high

 Q :Explain DRY and WET pipe Deluge system

Ans : WET pipe system (Water inside pipeline)

A wet pipe sprinkler system is a sprinkler system employing automatic sprinkler heads
attached to a piping system containing water and connected to a water supply so that
water discharges immediately from sprinklers opened by heat from a fire .
 DRY pipe system (air inside pipeline )

A dry pipe sprinkler system is sprinkler system employing automatic sprinklers that
are attached to a piping system containing air or nitrogen under pressure, the release of
which (as from the opening of a sprinkler) permits the water pressure to open a valve
known as a dry pipe valve, and the water then flows into the piping system and out the
opened sprinklers.
Dry pipe sprinkler systems are installed in areas where wet pipe systems may be
inappropriate such as areas where freezing temperatures might be expected.

 Q :Explain Safety integrity level

Ans: Safety Integrity Level (SIL) is defined as a relative level of risk-reduction
provided by a safetyfunction, or to specify a target level of risk reduction. In simple
terms, SIL is a measurement of performance required for
a SafetyInstrumentedFunction (SIF).

Safety Integrity Level. One of four possible discrete levels for specifying the safety
integrity requirements of the safety functions to be allocated to the safety-related
systems. SIL4 has the highest level of safety integrity; SIL1 has
the lowest.

In our koc GC fire and gas system we followed SIL 3

Q :Explain hot cold and warm redundancy

Ans:Cold redundancy is for non-critical processes where time is not a high priority and human
intervention is acceptable.

As an example, if a pressing machine fails, the automation system should notify the operator
and issue an alarm. A simple response may be to cut the power supply and displaying a red
alarm light. The operator can resume operation by simply starting another unit and requesting
service for the failing unit.

WARM redundancy

When time and response to a failure is more important but not critical, a warm redundancy
strategy may suffice if a temporary outage is acceptable.

As an example, if a valve fails to operate on a fluid transfer system, the pump can be disabled
and the system shut down. Depending on the process, the product may have a finite period in
which it will not be damaged, contaminated or start to deteriorate.

The cycle can tolerate a few seconds or minutes of interruption but the process must be restored
quickly and automatically to avoid any integrity issues.
PLCredundancy in warm systems usually operate in shadow mode where they run the identical
software and share a heartbeat signal from the primary to the secondary.

An interruption in control with the primary will result in the secondary assuming control.
Depending on the process train & components, extra arbitration circuitry may be needed to
mux control signals.

HOT redundancy
Warm & hot redundancy are similar in architecture but hot redundancy that offers instant
process correction when a failure is detected.

For example, in a mining or ore operation, if a primary controller for a conveyor fails, a backup
one should immediately assume control to avoid any delays in the transfer.

The PLC programming software & hardware coordination must be solid to allow for constant
messaging between processors and access to common data to allow for a smooth transition.

Data can be transferred between processors or accessed through a common database located on
the network. Either way, the secondary process must have knowledge of every logic cycle as to
where the primary left off.

 Q :Explain Intrinsically safe circuits

Ans :The electrical equipment which is installed in the hazardous area has to have only
intrinsically safe circuits. A circuit is intrinsically safe, when no spark or heat is able to ignite an
explosive atmosphere under fixed conditions. These predefined conditions include the normal
operation and certain failure modes.

 Q :Why do I need NFPA 72 compliance in fire and gas system

Ans :NFPA 72 is a prescriptive standard that applies to Fire Alarm Systems. While the NFPA 72 standard ma
no mention of gas detection, many clients are applying NFPA 72 standards and requirements to both fire and
gas detection systems. There are several advantages to NFPA 72 certified systems that include:
1.Allows for the combining of both fire alarm and gas detection functions
into a single safety system
2. Ensures that local "authorities having jurisdiction" like fire marshals or
fire authorities have assurance that the system complies with the applicable codes and standards
3.Allows the end-user to lower their insurance costs because they are
using a certified system
4. A NFPA 72 certified solution ensures that you are complying with the
best practices in the industry as drafted by the NFPA
 Q :Explain fail safe mode and how they are supervision all loops (EOL resistor) in
fire and gas system
Ans : The underlying principle of fail-safe design assumes that a process or item of
equipment can be designed to take the process to a safe status on equipment failure or
power interruption. This approach requires that the switch to “safe state” be possible
without power and that the “normal operating state” of the equipment utilize energized
control circuits.

Almost all detection, extinguishing and notification circuits of a Fire Alarm system are
not normally energized and are not “fail-safe”. In order to be sure these fire circuits are
intact and ready for use when needed these circuits are “supervised”. Supervision is
normally done using a small current or voltage passed through a field circuit device
called an “end of line device”. This small current or voltage is continuously monitored
to verify that the circuit is intact and ready for operation. Fire Alarm systems in many
cases need to activate suppression or notification equipment in the event of a hazardous
condition and these systems require power be available to do so. This is the primary
arguments behind the NFPA 72 requirements associated with backup power systems
and batteries.

EOL resistor using in koc 5.6kohms, 6.8kohms

 Q : why they using separate PLC system in fire and gas

Ans:NFPA72 standard says need separate plc system in fire and gas system

PLCs are best suited for medium to large size gas detection systems (25+ points of gas
detection). For very large systems, PLCs have the advantage of scaling fairly
inexpensively to accommodate large point counts. PLCs offer the added benefit of
extensive connectivity options for communicating with other DCS or ESD systems.

 Q:why they using time delay to co2 fire suppression deluge system

Ans : 30 Secs time delay

1. Man escaping time

2. To shut down ventilation fan and equipment’s
 Q :Hot replacement in ics triplex
 Ans: Hot Replacement The ability to remove and replace modules
Without removing power or stopping system operation.

 Q : Explain MTTR in fire and gas system

Ans : MTTR means Mean time to repair
8 Hrs time to troubleshooting fault in (2 out 3 and 1 out 2 ) voting group
Otherwise F & G system will give trip signal

 Q :What is Redundancy in plc system

Ans :The employment of two or more devices, each performing the same function, in
order toimprove reliability.
 Q :TMR means in ics plc system
Ans : Triple Modular Redundancy.
 Q : NFPA standard in ics plc system

Ans : The 8000 system is certified to be used in NFPA 86 compliant systems.

The systems should be integrated in accordance with NFPA 86. In particular the
following shall be applied.
• The supplier of the application software for the programmable controller shall
provide the end user and the authority having jurisdiction with the documentation
needed to verify that all related safety devices and safety logic are functional
before the programmable controller is placed in operation.
• In the event of a power failure, the programmable controller (hardware and
software) shall not prevent the system from reverting to a safe default condition. A
safe condition shall be maintained upon the restoration of power.
• The control system shall have a separate manual emergency witch, independent
of the programmable controller, that initiates a safe shutdown.
• Any changes to hardware or software shall be documented, approved, and
maintained in a file on the site.
• System operation shall be tested and verified for compliance with this standard
and the original design criteria whenever the programmable controller is replaced,
repaired, or updated.
• Whenever application software that contains safety logic or detection logic is
modified, system operation shall be verified for compliance with this standard and
the original design criteria.
• The NFPA certification is only applicable where the system is applied in
accordance with the safety manual and NFPA86 requirements.
• A programmable controller not listed for combustion safety service shall be
permitted to monitor safety interlocks, or to provide burner control functions,
provided that its use complies with both of the following:
(1) The programmable controller shall not interfere with or prevent the operation of
the safety interlocks.
(2) Only isolated programmable controller contacts (not directly connected to a
power source) shall be permitted to

 Q : Types of plc languages

1. Ladder logic
2. Functional block
3. Sequential functional chart
4. Structured text
 Q : OPC server means
Ans : OLE process control
O-object, L- linking, E-embedding
This server used for communicate with 3 rd party plc to main supervisor controller(dcs)
 Q : Explain basic features of ICS plc system
Ans :
1. Working under SIL 3 logic
2. Triplicated circuits with each module.
3. Line monitoring system
4. Each analog input channel has triplicated a/d converters
5. 1msec resolution
6. Self-fault tolerance system
7. Hot replacement modules
 Q : Draw logic gates
Ans:
  Q : Draw triple redundancy plc system diagram

Ans:
  Q :Draw double redundancy system diagram
Ans :

 Q : Explain LEL andUEL

Ans :

LEL and UEL

LEL means “lower explosive limit” and UEL means “upper explosive limit”. The number is
expressed in percent, and means the volume percent of vapor (or gas) in air. For example,
pentane has a LEL of 1.50% and a UEL of 7.8%. Its flash point is –57oF. It has a boiling point of
97oF. The NFPA classifies pentane as a Class I A Flammable Liquid. If the volume percent of
pentane in air is less than 1.5%, the mixture is considered too lean to ignite. If the volume
percent of pentane in air is greater than 7.8%, the mixture is too reach to ignite (not enough
oxygen). The actual ignition will take place with explosive violence especially if the
concentration of pentane in air is somewhat midway between the UEL and LEL numbers.

The 1.5% concentration of pentane in air is equivalent to 15,000 parts per million (ppm)
concentration. The 7.8% conentration is equivalent to 78,000 ppm.

The LEL and UEL percentages are for mixtures of the pure gas or vapor in air. If the mixture is
enriched with oxygen, the spread between these two numbers will be greater, perhaps much
greater. In other words, the LEL will be less than 1.5% and the UEL will be greater than 7.8%.
The same is true if other oxidizers are present.

Q : What are the Extinguishing systems used in Fire and Gas System and why it is
necessary?

Extinguishing system is necessary to protect Valuable equipments and human. Halon

System, CO2, FM 200, DCP, Foam, Water etc.
 Q: What type of cables used in Fire and Gas System?
Ans:MICC (Mineral Insulated Copper Conductor), Heat resistant Cables (Pirelli), Lead Sheathed
Cables and XLPE (Cross Linked Poly Ethylene)
 Q : What is the difference between addressable and non-addressable system
Ans :addressable detector means we can easily identify and access immediately in loop

Non addressable means we can identify area only not particular location or room in
building

 Q : Draw resistance in series and parallel

Ans : Resistance in series connection and calculation

Resistance in parallel connection and calculation

 Q : Classification of zones.

Zone 0 – Hazardous zone in which flammable atmosphere is continuously present for

long period or more than 1000hr/year.

Zone 1 – Hazardous zone in which flammable atmosphere is likely to occurs under

normal operations or 10 to 1000 hrs/year.

Zone 0 – Hazardous zone in which flammable atmosphere is present only abnormal

condition or break downs or typically 10hr/year.