Installation & Commissioning of Explosive Gas Detection System

INSTALLATION & COMMISSIONING OF EXPLOSIVE GAS DETECTION SYSTEM SIC00233
-Electronically Approved Drawing-Checked: Lascialfari G., Approved: Arcioni M.-Internal DT-'N'

STANDARD PROCEDURE FOR VERIFICATION OF THE CORRECT INSTALLATION AND
COMMISSIONING OF
EXPLOSIVE GAS DETECTION SYSTEM

AT SITE
REPLACES RIC8952005
TITLE: DOCUMENT CODE REVISION

INSTALLATION & COMMISSIONING OF EXPLOSIVE GAS DETECTION SYSTEM
SIC00233 0
REVISION DESCRIPTION: APPROVED Electronically Stored
ISSUE REVISION DATE SECURITY CODE
CHECKED Electronically Stored
15-Dec-16 N
EXECUTED ISSELnord
SCALE REPLACES/DERIVED FROM 1st EXECUTION ORIGINAL JOB SIZE LANGUAGE
N/A RIC8952005 15-Dec-16 NA 4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF Nuovo Pignone Tecnologie S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, SHEET
EXCEPT WITH THE WRITTEN PERMISSION OF Nuovo Pignone Tecnologie S.r.l. UNPUBLISHED WORK ©2016 Nuovo Pignone Tecnologie S.r.l. ALL RIGHTS RESERVED
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Contents
1 SCOPE ............................................................................................................................................................................. 3
2 GENERAL ....................................................................................................................................................................... 3
2.1 Reference documents and drawings 3
2.2 Instrumentation needed for verifications 3
3 INSTALLATION ............................................................................................................................................................ 4
3.1 General guidelines for best detector location 4
3.2 General verification & checks 5
3.3 Specific verification & checks 6
4 CALIBRATION AND FUNCTIONAL TEST ........................................................................................................... 9
4.1 General procedure for Gas Detectors calibration 9
4.2 General procedure for Gas Detection System functional check 11
5 MAINTENANCE ........................................................................................................................................................ 13
5.1 General Gas Detector’s maintenance guidelines 13
6 CERTIFICATIONS ..................................................................................................................................................... 13
Requirements and Limitations
This Procedure is being delivered for general guidance purposes, in order to provide technical background
information needed for carrying out Field Activities relevant to GE Oil & Gas Products, such as installation,
commissioning, startup, maintenance and troubleshooting.
Performing of Field Activities on the Products entails the use of complex technical Products that requires using
special tools and expert know-how. Only technically qualified personnel should perform Field Activities on the
Products.
Field Activities on the Products performed by unauthorized personnel may be dangerous and may invalidate any
warranty provided by GE Oil & Gas and which may otherwise apply to the Products.
Any and all risks associated with the use of this Procedure by Customer shall be entirely borne by Customer.
In no event shall GE Oil & Gas be liable whether in contract, warranty, tort (including negligence (whether active,
passive or imputed), product liability or strict liability or other theory), for cover or for any indirect, incidental,
special or consequential damages (including without limitation any loss of profits or data, business interruption,
computer failure or other pecuniary loss) arising out of the use or inability to use this Procedure or the
performance of any field activity.
This procedure and any and all information set forth therein are proprietary to GE Oil & Gas; therefore, Customer
agrees not to assert any proprietary rights therein, or to represent this Procedure and/or any information set forth
therein to anyone other than as a document and/or information which is exclusively proprietary to GE Oil & Gas.

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1 SCOPE
This procedure provides general guidelines on the checks and tests to be carried out on
the “EXPLOSIVE GAS DETECTION” System for GAS TURBINES during installation and
commissioning.
2 GENERAL
2.1 Reference documents and drawings
ITN66383.01 HONEYWELL GAS SENSORS
ITN66370 DEC TRONIC
ITN66368 & ITN66382 MSA
SOM6658573 Gas Detector Duct mounting assembly dwg
SMO1456821 Sampling system for flammable and toxic Gas Detectors
Technical specification
Manufacturer manual
CEI standards
P&ID and Instrument List
Primary and secondary Hook-up
Wiring Diagram
I/O & Instrument List
F&G System Logic Diagram
Cause & effect Diagram
Unit Control Panel Layout & Construction Drawing
Control System Schematic
Control Loop Schematic
2.2 Instrumentation needed for verifications
-Common tools (mm/inch.)
-Tester
-Calibration kit ( Sample gas bottle, Alignment kit, Interrogator, etc. )

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3 INSTALLATION
The gas detector checks the presence of a selected gas in atmosphere (noxious or
dangerous gas). There are three main categories of gas sensor used on O&G typical
installation: Catalytic, Infrared and Electrochemical cell.
On GE O&G products these instruments are generally located in turbine compartment,

accessory compartments and in the inlet air system.
3.1 General guidelines for best detector location

There are no standard rules for detector placement, since the optimum detector
location varies with the application.
The following factors are given as reference to be considering when selecting a

detector location:
- When locating sensors consider the possible damage caused by natural events e.g.
rain or flooding (if in open areas).
- The sensor should be located in an area where it is safe from potential sources
of contamination that could poison the sensing element.
- The sensor should be pointed down to prevent the buildup of contaminants on the
gas inlet.
- Consider ease of access for functional testing and servicing.
- Consider how escaping gas may behave due to natural or forced air currents.
- Emission temperature and vapor density of the gas. The gas detector should be
located near the floor for gas vapors, which are heavier than air.
- Locate the gas detector where prevailing air currents contain the maximum
concentration of gas.
- Locate the gas detector as near as possible to the likely source of a gas leak.
- Mount the gas detector away from sources of excessive vibration. Exposure to
excessive vibration can result in premature failure of electronic devices and
should be avoided if possible.
Warning! Check if max allowable working temperature of the sensor is higher than the
ambient temperature of the installation locations, since the presence of high
temperature zones can damage the primary sensor or electronic.

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3.2 General verification & checks
Verification of conformity of the instrumentation with the specification.
Verification of integrity of the components.
Verification of correct position of explosive gas detectors in the areas indicated on

the P&ID.
Verification of the correct installation/orientations of explosive gas detectors

according to the model type.
Verification on the fire fighting control panel of correct wiring of the power supply
cables and of the cables coming from the field.
Verification of correct wiring of the cables exiting from the control panel toward the
UCP.
Verification of field connections both with the instrument and with the junction box.
Verification of connections in the junction box toward the control panel.
Verification of operation of gas sensors with the gas type to be detected

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3.3 Specific verification & checks

For Open Path sensor type, typically used in the inlet air system, light transmitter
and receiver distance shall be verified; since some sensor parameters (like accuracy
and stability) are influenced from this distance and the measure deviation is greater
when the distance increase.
Pay attention to any obstruction in the beam path such as dust, rain, snow, mobile
equipment, personnel, ladders, etc.
Special equipment ( alignment kit ) it necessary to carried out the alignment between
light transmitter and receiver.
Refer to sensor manufacturer’s manual for alignment procedure details.
For Duct Mounting sensor type, check if the sensor sampling points are installed in a
straight ventilation outlet duct zone. The sensors sampling point should have an
upstream straight duct of at least 3 times the duct width dimension and a
downstream straight duct of at least 2 times the duct width, in order to provide
uniform and non-turbolent air flow and a homogenous air/gas mixing.

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It is important to check that all the holes on the “Inlet tube-Pitot” are within the
duct and also that these ones are oriented to the air flow ( see picture below ).
Pay particular attention on the installation of the two sampling pipes inside the ducts.
Refer to SOM6658573 for more details.
For Sampling System sensor type, in order to ensure the correct operation of the
sampling system, it’s important to follow the instructions to assembly the Pitot tube
on the duct; check that all the holes on the tube are within the duct and also that
the air flow is tangent to the pitot tube holes.
The holes MUST NOT be oriented to the air flow
Pay attention to the Ejector direction; refer to following picture for details:

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Avoid pressurizing calibration gas inside the units measurement path by keeping gas
flow rates below the maximum recommended flow levels
(2 L / min) and ensuring that gas can freely vent to atmospheric pressure.
Recommended flow rates during normal operation are 1 L / min
Refer to SMO1456821 for additional details.

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4 CALIBRATION AND FUNCTIONAL TEST

4.1 General procedure for Gas Detectors calibration
Warning! Before performing any Gas Sensor calibration, verify that the Fuel Gas
manual isolation valves are in the fully close position and verify that the Fire
Fighting System has been isolated and locked ( Apply safety procedures such as
LOTO ). Pay particular attention to visual warnings (lights on the compartment,
light signals on the doors, etc...) and audio warnings (horns) that may be activated
during the Gas Sensor calibration.
There are different calibration procedures based on gas sensor model type,
manufacturer, control unit or transmitter connected.
Always refer to manufacturer’s manual for the correct procedure to calibrate the
sensor.
The procedures described below are generic and are valid for any kind of
“catalytic” sensor type:
There are two stages to calibrate gas detectors: the “zero” and the “span”
adjustment:
ZERO adjustment
- Ensure that the area around the detector is clean and free from gas or other
contaminants.
- Enter calibration mode on the electronic card on the UCP or transmitter in the
field (depending on site configuration), check the instrument/card manual for
correct buttons/LED sequences.
Depending of the manufacturer, when entering calibration mode, the ZERO
of the card will be made automatically; if not, select sensor ZERO from
the configuration menù of the card/transmitter and calibrate it

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INSTALLATIO
ON & COMMISSSIONING OF EX
XPLOSIVE GAS DETECTION S YSTEM SIC00233
SPA
AN adjustm
ment
- EEnsure youu are usinng the apppropriate calibration

c gas cylinnder
- PPlace the cup from the samplle gas botttle over the sensoor
- AAfter this, apply thhe calibrattion gas oppening thee valve onn top of thhe bottle.
- OOn the carrd or trannsmitter, sselect thee SPAN caalibration m menù and calibrate the
SSPAN. Typical calibbration gaas concenntration is 50% L .E.L. but it can vary v
bbetween 40%
4 and 60%.
- WWhen SPA AN calibration is cooncluded, close the valve onn the calibration vaalve
bbottle andd ensure that sensoor reading change too show ann ambient condition.
Aftter a succcessful callibration, rremove thhe cup from the sennsor and return
r all the
ms to theiir approprriate locat ion in the Calibratioon Kit.
item
Warning!
Durring calibraation avoid the exp osure of the “Catallytic” senssor type to
t high
conncentrationns of combbustible g ases for extended periods thhat may inntroduce
stress to the sensing element aand seriouusly affectt its perfoormance. In case of
exttended perriods of coombustiblee gas, recaalibration should im mediately be
perrformed, and the sensor shouuld be replaced if necessary.
TITLLE: DOCUMENT CODDE REV
VISION
INSTTALLATION & COM
MMISSIONING OF EEXPLOSIVE GAS DETECTION
D SYSTEM
SI C00233 0
REVISION DES
SCRIPTION: PAAGE MARKER SECURITY CODE
ISSUE N/A N
ORIGINNAL JOB SIZE LAN
NGUAGE
NNA 4 A
THIS DOCUMENT IS AND CONTAINS CON NFIDENTIAL AND PROP
PRIETARY INFORMATIO ON OF Nuovo Pignone e Tecnologie S.r.l. WH
HICH SHALL NOT BE USSED OR DISCLOSED TO O OTHERS, SH
HEET
EXCEPT WITTH THE WRITTEN PERM
MISSION OF Nuovo Pignone Tecnologie S.rr.l. UNPUBLISHED WORK ©2016 Nuovo Pig gnone Tecnologie S.r.l.l. ALL RIGHTS RESERVED
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4.2 General procedure for Gas Detection System functional check

Prior to start gas detection system functional check all installation requirements
must be successfully completed, witnessed and signed-off.
It is also required that all gas detection sensors are already calibrated and loop-
checked.
Each gas detector should be tested according to the procedure explained below:
The activation of a sensor (generally 5% of Low Explosive Limit – LEL. Refer to
site specific documents for exact value) within a loop generates a gas alarm
signal (1oo3), whereas the activation of at least two sensors (generally 10% LEL)
within a loop generates a gas trip signal (2oo3).
In any case, to know the correct sequences, refer to “FIRE & GAS PLC LOGIC
DIAGRAM”.
Power up the instrument by closing the respective disconnect terminals or by
reconnecting the conductors.
Once the sensor is powered, a “warm-up” time of at least 30 minutes is required
before the check can be performed.
Using the appropriate adaptor, connect the calibration kit with the specimen tank
to the sensor.
Perform the functional test of the instruments with the aid of the sampling
cylinders and verifying the findings on the Fire & Gas control panel taking in
consideration sample gas composition as indicated on the bottle certificate (i.e.
introducing methane at 2.5%, being methane LEL =5%, control panel should reports
an indication of 50% LEL).
For each sensor, check the alarm signal acquisition on the Fire & Gas Control
Panel and the activation of exchange signal with the Unit Control Panel.
Visual check for HMI Video pages: verify the correct visualization of analog
values, correct visualization of event type (alarm, trip, and fault) and video
animations.
Then remove the adaptor, the calibration kit and the sampling cylinder and check
that the display returns to the actual ambient values.

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Finally, unhook a sensor wire and check that the Fault signal is reported on the
fire prevention control unit.
Before and after the test, check that the sensor is not contaminated with oil,
steam, dust, etc because its sensitivity could be drastically reduced.
During the various test phases, check the correctness of the alarm/trip sequence
initiated from within the F&G system is correct.
Demonstrate, if applicable, any cutout signals activation (ventilation fans, exhaust
blowing fans, extractor fans, etc.)
This sequence must correspond to the supplier specifications and that indicated in
the functional description of the system.
Pay particular attention to visual warnings (lights on the compartment, light

signals on the doors, etc...) and audio warnings (horns).

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5 MAINTENANCE
5.1 General Gas Detector’s maintenance guidelines
Gas sensor need to be calibrated and periodically checked to ensure sensor

accuracy and system integrity.
Gas Sensor standard maintenance periodic program are:

Catalytic and Electrochemical detectors: every 3 or 4 months depending on the
plant and application.
Infrared detectors: every 6 months. It can be reduced depending on the plant and
application.
However, it is good practice to check often the sensor during the first 30 days
after installation. During this period, it is possible to observe how well the
sensor is adapting to its new environment.
Refer to sensor manufacturer’s manual for recommend time interval between

calibrations.
6 CERTIFICATIONS
The certification, documenting correct installation and performed execution of the

verifications, is enclosed as a fac-simile.

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SERVICE REPORT No. SIC00233
g GE Oil & Gas Sheet 1 of 1

INSTALLATION/COMMISSIONING CERTIFICATION FORM
Date:
EXPLOSIVE GAS DETECTION SYSTEM
Item code:……………………………………………………… Job Number:………………………………………………………
Service: GAS DETECTION Ref. Service Instruction No. SIC00233

POS. ACTIVITY VERIF. DATE NOTE
Conformity of the instrumentation with the
1
specification
2 Integrity of component parts
3 Correct positioning of gas detectors
Correct installation/orientation of the gas

4
detectors according to the model type
Wiring of power and signal cables to the

5 control panel in compliance with connection
diagrams
Field wiring of instruments and terminal strips in

6
junction box in compliance with connection diagram
7 Correct calibration of gas detecting sensors

8 Correct operation of gas detecting sensors
Contractor GE Oil & Gas Final Client:

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Installation & Commissioning of Explosive Gas Detection System

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INSTALLATION & COMMISSIONING OF EXPLOSIVE GAS DETECTION SYSTEM SIC00233

-Electronically Approved Drawing-Checked: Lascialfari G., Approved: Arcioni M.-Internal DT-'N'

EXPLOSIVE GAS DETECTION SYSTEM

TITLE: DOCUMENT CODE REVISION

Requirements and Limitations

TITLE: DOCUMENT CODE REVISION

2.2 Instrumentation needed for verifications

-Common tools (mm/inch.)

-Calibration kit ( Sample gas bottle, Alignment kit, Interrogator, etc. )

TITLE: DOCUMENT CODE REVISION

On GE O&G products these instruments are generally located in turbine compartment,

3.1 General guidelines for best detector location

The following factors are given as reference to be considering when selecting a

TITLE: DOCUMENT CODE REVISION

3.2 General verification & checks

Verification of conformity of the instrumentation with the specification.

Verification of integrity of the components.

Verification of correct position of explosive gas detectors in the areas indicated on

Verification of the correct installation/orientations of explosive gas detectors

Verification of connections in the junction box toward the control panel.

Verification of operation of gas sensors with the gas type to be detected

TITLE: DOCUMENT CODE REVISION

3.3 Specific verification & checks

Refer to sensor manufacturer’s manual for alignment procedure details.

TITLE: DOCUMENT CODE REVISION

The holes MUST NOT be oriented to the air flow

TITLE: DOCUMENT CODE REVISION

Recommended flow rates during normal operation are 1 L / min

Refer to SMO1456821 for additional details.

TITLE: DOCUMENT CODE REVISION

4 CALIBRATION AND FUNCTIONAL TEST

TITLE: DOCUMENT CODE REVISION

- EEnsure youu are usinng the apppropriate calibration

4.2 General procedure for Gas Detection System functional check

TITLE: DOCUMENT CODE REVISION

Pay particular attention to visual warnings (lights on the compartment, light

TITLE: DOCUMENT CODE REVISION

Gas sensor need to be calibrated and periodically checked to ensure sensor

Gas Sensor standard maintenance periodic program are:

Refer to sensor manufacturer’s manual for recommend time interval between

The certification, documenting correct installation and performed execution of the

TITLE: DOCUMENT CODE REVISION

SERVICE REPORT No. SIC00233

g GE Oil & Gas Sheet 1 of 1

EXPLOSIVE GAS DETECTION SYSTEM

Item code:……………………………………………………… Job Number:………………………………………………………

Service: GAS DETECTION Ref. Service Instruction No. SIC00233

3 Correct positioning of gas detectors

Correct installation/orientation of the gas

Wiring of power and signal cables to the

Field wiring of instruments and terminal strips in

7 Correct calibration of gas detecting sensors

Contractor GE Oil & Gas Final Client:

TITLE: DOCUMENT CODE REVISION

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