MOL HUNGARIAN OIL AND GAS PLC.

R&M Division

MOL Group

TECHNICAL SPECIFICATION
INSTRUMENTATION

6. Control Systems
10. Design of gas alarm systems

MGS-M-REF-I-6.10

Rev 1.00.00

www.mol.hu

This document is property of MOL Group. The use is only allowed with the written permission of MOL Group.
 MOL HUNGARIAN OIL AND GAS PLC. MGS-M-REF-I-6.10
R&M Division
TECHNICAL SPECIFICATION - INSTRUMENTATION Rev.: 1.00.00
6 Control Systems Date: 30.11.2011
10 Design of gas alarm systems Page/Pages: 2/6

Release list
Rev. Date Description Edited Verified Approved
0.00.00 31.10.2008 Basic release
0.00.01 01.11.2011 General review F. Nagy
1.00.00 30.11.2011 General issue F. Nagy I. Kovács

This document is property of MOL Group. The use is only allowed with the written permission of MOL Group.
 MOL HUNGARIAN OIL AND GAS PLC. MGS-M-REF-I-6.10
R&M Division

Contents
Release list ................................................................................................................................................................... 2
Design of gas alarm system ......................................................................................................................................... 4
1 General .................................................................................................................................................................. 4
2 Applicable standards ............................................................................................................................................. 4
3 Definition of terms.................................................................................................................................................. 4
3.1 Lower explosion limit (LEL)........................................................................................................................... 4
3.2 Lower explosion point ................................................................................................................................... 4
3
3.3 Long term exposure limit (ppm or mg/m ) .................................................................................................... 4
4 System design ....................................................................................................................................................... 4
4.1 Field installed detectors ................................................................................................................................ 4
4.2 Central unit of the atmospheric gas contamination detection system .......................................................... 4
4.3 System configuration .................................................................................................................................... 5
5 Criteria for selecting and erecting field detectors .................................................................................................. 5
5.1 Detectors for flammable gases ..................................................................................................................... 6
5.2 Detectors for toxic gases .............................................................................................................................. 6

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 MOL HUNGARIAN OIL AND GAS PLC. MGS-M-REF-I-6.10
R&M Division

DESIGN OF GAS ALARM SYSTEM

1 General
This specification summarises the general requirements applicable to the design of systems installed in facilities to
detect gas contamination in the atmosphere. During the installation of a facility or plant the project specification
applicable to the specific facility may contain deviations from this document. In case of deviation the requirements
set forth in the project documents shall govern.
The project specification may contain deviations from, or changes in, these requirements. Any deviation from the
content of this specification or from the project specification will be possible with a written approval thereof by the
competent expert in the area at MOL Group only.

2 Applicable standards
According to MGS-M-REF-I-4 & MGS-S-REF-I-4

3 Definition of terms
3.1 Lower explosion limit (LEL)
Such concentration of flammable gas or vapour in the atmosphere below which the gaseous medium cannot
explode.

3.2 Lower explosion point

Such a temperature of flammable liquid at which the concentration of saturated vapour in the atmosphere coincides
with the lower explosion limit.
3
3.3 Long term exposure limit (ppm or mg/m )
Such a concentration of toxic gas in the atmosphere over which the long term (8 hours) exposure can be human
dangerous.

4 System design
4.1 Field installed detectors
1. The installation location for the field detectors of the atmospheric gas contamination detection system shall
be approved by MOL Group HSE (Health, Safety and Environment) organisation with due consideration of
the hazardous area classification of the specific facility or of the occurrence of toxic substances.
2. Detector shall be mounted at locations where the probability of mechanical damages, external effects
(steam, water, dust) is minimal. In case this cannot be ensured the detectors shall be equipped with
mechanical protection (such as protective cover or screen).
3. The detectors shall have protective hoods against water or moisture, and hydrogen detectors shall have a
collecting cone.
4. For detectors mounted at high elevations or not accessible without the use of aids, stainless steel or plastic
sampling tube shall be installed in order to enable introduction of test or calibration gas to the detectors.
The end of the sampling tube shall be located in a location mechanically protected (e.g. against wasps,
spiders, water and dust) and accessible for the maintenance personnel without any aid.

4.2 Central unit of the atmospheric gas contamination detection system

1. The gas contamination detection system applied shall have a central unit.
2. The central unit of the atmospheric gas contamination detection system shall be located on the main board
or in an instrument cabinet in the control room.
3. The central unit shall be of modular design, with possibility for extension and configuration per channel.
4. The voltage levels required for the detectors and signal-processing cards shall be provided by the internal
power supply unit of the system.
5. The central unit of the atmospheric gas contamination detection system shall be powered from UPS.
6. The signal processing cards shall include a sufficient number of pre-alarm, emergency alarm and self-
diagnostic failure/error outputs, as required by system configuration.

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7. The output relays of processing cards shall be free of any error or fault and in closed contact in their
energised (default) position.
8. Processing cards shall be configured in a manner that, when the gas concentration causing an alarm
ceases to exist, the relays shall return to their default position.
9. Plates with the serial numbers of channels and with the location of their in-field/ at-plant installation shall be
placed in the direct vicinity of the central unit (e.g. next to heat exchanger E102).
10. If an intelligent process control system (hereinafter: ICS) is in place at the facility equipped with field
instrumentation management system (hereinafter: FIMS) no need to install central unit. In this case all the
detectors directly connected to ICS using 4-20 mA and the field detectors have to connect to the FIMS.

4.3 System configuration

1. The atmospheric gas contamination detection system shall include the indoor and/or outdoor detectors, the
central signal processing unit (signal processing cards, power supply unit, support rack, diagnostics and
monitor cards), strobe lights installed in process/field areas, alarm horn, audible alarm acknowledge button,
and test button to check the functionability of the audible and visual alarms.
2. In process areas where the noise level is high, warning (strobe) lights shall be mounted at easily visible
locations (if required at several locations) giving a flashing warning signal if an emergency (HH)
concentration is detected by any of the gas contamination detectors associated with a specific area. The
flashing light shall keep on until the level of the gas contamination detected by all detectors associated with
the system drops below the emergency maximum level.
3. At a central location in the plant area a warning horn shall also be installed. The horn shall give an audible
signal if emergency (HH) concentration is detected by any of the gas contamination detectors associated
with the system until the audible alarm acknowledge button is pushed.
4. In case instrument air is available near the installation location of the warning horn, the warning horn shall
be pneumatically operated. In case instrument air or other utility (e.g. inert gas) required for the horn
operation is not available, or the connection of the instrument air to the warning horn would result in
disproportionately high costs, use of an electrical operation horn is permitted.
5. The logic used to trigger, acknowledge and test acoustic or light alarms can be developed in the following
manner:
By using a safety PLC, or
By using relay-based logic.
6. If a trip-off needs to be triggered for the gas contamination limit value, it can be done in the following
manner:
By using a safety PLC, or
By using relay-based logic.
7. If an intelligent process control system is in place at the facility, the ICS shall display and log the following
alarms :
atmospheric gas contamination high (H) pre-alarm (e.g. high at 20% LEL per detector);
atmospheric gas contamination high-high (HH) alarm (e.g. HH at 40% LEL per detector);
common failure alarm of atmospheric gas contamination detection system;
audible alarm acknowledge button pushed;
light/lamp and horn test button pushed.
8. If the installation location of the central unit for the atmospheric gas contamination detector is manned on a
continuous basis by operators, it is sufficient to have a common alarm on the ICS for high and high-high
gas contamination alarms, otherwise display by channel is required. Forwarding of signals to the ICS can
be done either via a serial bus (e.g. Modbus) or by way of individual cabling.
9. Signal processing boards shall be set to the gas to be detected (sensitivity, alarm levels).

5 Criteria for selecting and erecting field detectors

The explosion protection of field detectors shall comply with the hazardous zone classification of the specific
installation location.
For the connection of detectors operating on catalytic principle the following aspects must be observed in order to
reduce line resistance:
use of solid conductor cables;

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if possible, no junction box shall be used;

use of cables with conductor of large cross-sections for long distances.
The scaffold holding the detectors that measure flammable and toxic gases shall be painted red and yellow,
respectively.
The metal housing and holding scaffold of sensors/ detectors shall be connected to the unit’s ground network
(EPH).
It is preferred to use sensors/ detectors/ transmitters that have self-diagnostic mechanisms.

5.1 Detectors for flammable gases

1. Gas detectors working on catalytic and infrared light absorption principle shall be used.
2. If the flammable gas is always present at the installation site at a low concentration, and there is a need for
rapid detection, the installation of an infrared light absorption gas detector is recommended.
3. Hydrogen detectors shall be equipped with collection cones.

5.2 Detectors for toxic gases

1. Gas detectors measuring on the basis of electrochemical principle shall be used.
2. The structural material of the detectors shall be suitable for the specific environment (e.g. hydrogen-
sulphide detectors must not have brass glands).

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