PTSC Lam Son FPSO

Z1 11.03.2014 Final RC RC RC
PTSC rev. Date Reason for issue Prep. Checked Accepted
Sub-contractor logo Contract no. / Purchase order no.:
Kongsberg Maritime Engineering Pte. Ltd. (if any):
81 Toh Guan Road East
#04-01 Secom Centre PTSCAP-2012-CO-005
Singapore 608606

Doc. title according to SMDR:

Inergen System Operation and

Maintenance Instruction

Tag no.: System no.: SFI code: KME sub-contractor document no._Rev.:
XY_Z
LSJOC document number
Project code PO no. Unit code Disc. code Doc. type Sequence no. Rev.
TLDD - 3003 - 5AA - K - T02 - 0001 D1
PTSC document number
Project no. Orig. code Disc. code Doc. type Sequence no. Total no. of Pages Rev.
0909 - KM - I - MB - 00001 16 Z1
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The following maintenance procedures and intervals are the minimum requirements for maintenance of Archer
IG-541 systems. These procedures do not preclude those required by NFPA 2001, and/or the authority having
jurisdiction. More frequent service intervals may be necessary if systems are installed in more severe service
applications. This document excludes maintenance procedures for HVAC and other auxiliary equipment that
are connected to the IG-541 system. Consult the appropriate vendors for those procedures.

1. INSPECTION AND MAINTENANCE TABLE

S/N Part Name Service Type Procedure Corrective action Frequency

A Discharge Inspection 1. Check pipe and 1. Repair any defects. If Semi-
Piping fittings for signs of pipes or fittings are Annually
corrosion and found to be severely
damage. damaged or
2. Check that the paint corroded, these parts
is in good condition should be replaced
and that there are no immediately by an
exposed metal authorized installer.
surfaces. Upon replacement of
3. Check all pipe part, the discharge
supports/hangers are piping shall be
securely installed and pressure tested in
in good condition. accordance to
specifications in
drawing no. ARC-
AKS-LP-PNID.
2. If paint is found
missing or chipped in
places, apply paint
(this should be
marine grade paint
minimum) in signal
red to the affected
area.
B Discharge Inspection 1. Check the nozzle Repair and/or replace as Semi Annually
Nozzles orifices are clear and necessary.
unobstructed.
2. Check that the nozzle Note: All nozzle locations
orifices are not and type should be
showing signs of recorded and reported to
corrosion. Archer for a replacement
3. Check piping thread with correct orifice size.
for the nozzle to be in
good condition.
C1 Agent Inspection 1. Check the pressure 1. Return the cylinder Quarterly
Storage gauge at each for recharge by an
Cylinders cylinder for pressure authorized fill station
loss, as adjusted for (See section 4 of this
temperature (See Fig document for
2 section 6), exceeds procedures of
10% of the nominal removing the
pressure (200bar at cylinders).
25⁰C). 2. If paint is found
2. Check that the missing or chipped in
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cylinder paint is in places, apply paint
good condition. (this should be
3. Check the cylinder marine grade paint
and valve for signs of minimum) in signal
damage or corrosion. red to the affected
Isolate the relay box area.
before inspection. 3. If cylinders are found
to be severely
Note damaged or there
The control panel and limit are signs of severe
switches must be disabled corrosion, please
and the pneumatic actuators return the cylinders
removed – before any work to an authorized
is carried out on the system.
Ensure that the discharge
dealer for re-
outlet cap is fitted to the inspection and
valve and cylinder replacement if
immediately after the necessary
cylinder is disconnected from
the discharge hose.

C2 Agent Testing 1. Hydrostatic test. 1. Cylinders will need to 10 years

Storage Isolate the relay box be sent to an
Cylinders before inspection. authorized vendor for
refill, recharge,
internal inspection
and hydrostatic test.
A hydrostatic test
certificate should be
given. (See section 4
of this document for
procedures of
removing the
cylinders).
D CO2 Pilot Inspection 1. Weigh the CO2 1. Return the cylinder Quarterly
Cylinders cylinder with a for recharge. Contact
calibrated scale and Archer for more
make sure it is not details.
below 90% the 2. If paint is found
nominal weight missing or chipped in
(5.6kg). places, apply paint
2. Check that the paint as required.
is in good condition.
3. Check the cylinder for
signs of corrosion.
Isolate the relay box
before inspection.
E Selector Inspection 1. Check that the paint 1. If paint is found Semi-
Valves is in good condition. missing or chipped in Quarterly
2. Check the valves for places, apply paint
signs of corrosion. (this should be
Isolate the relay box marine grade paint
before inspection. minimum) in signal
red to the affected
area.
F1 Manual/ Inspection 1. Check for signs of Replace the actuators if Semi-Annually
Pneumatic corrosion and found corrosion or
Actuators physical damage. physically damaged.
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Isolate the relay box
before inspection.
F2 Manual/ Test Performance test Replace the actuators if Annually
Pneumatic 1. Disconnect the found faulty or unable to
Actuators manual/pneumatic actuates.
actuator and turn
down the lever and
check that it actuates.
2. Disconnect the
manual/pneumatic
actuator and connect
it to an external
pressurized cylinder
with nominal pressure
(20bar). Check that
the manual/pneumatic
actuator actuates.
Isolate the relay box
before inspection.
G1 Pneumatic Inspection 1. Check for signs of Replace the actuators if Semi-Annually
Actuators corrosion and found corrosion or
physical damage. physically damaged.
Isolate the relay box
before inspection.
G2 Pneumatic Test Performance test Replace the actuators if Annually
Actuators 1. Disconnect the found faulty or unable to
manual/pneumatic actuates.
actuator and connect
it to an external
pressurized cylinder
with nominal pressure
(20bar). Check that
the manual/pneumatic
actuator actuates.
Isolate the relay box
before inspection.
H Time Delay Inspection 1. Check condition of 1. If paint is found Annually
Units paint. missing or chipped in
2. Check for signs of places, apply paint
corrosion and (this should be
physical damage. marine grade paint
Isolate the relay box minimum) in signal
before inspection. red to the affected
area.
I Signage Inspection 1. Check for signs are 1. Replace sign if they Quarterly
and readable and in the are unreadable.
Operations correct locations. See 2. Repair the mounting
Instructions drawings (ARC-AKS- of the signs.
LP-DIP pg79-92).
2. Check that all signs
are securely mounted
and in good condition.
Isolate the relay box
before inspection.
J Protected Inspection 1. Determine whether Contact Archer for more Annually
Space boundary details.
penetrations or other
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changes to the
protected enclosure
have occurred that
could affect leakage
and extinguishing
performance.
Isolate the relay box
before inspection.
K1 Limit and Inspection 1. Check the switches 1. Replace the switches Annually
Pressure for signs of corrosion if found corroded or
Switches and physical damage. physically damaged.
2. Check that all wiring 2. Tighten any loose
is terminated securely terminations.
and in good physical 3. Replace all cables
condition. that are physically
3. Check that cable damaged or if there
sheaths are intact i..e is exposed metal
no exposed metal conductor
conductor
4. Check that all cable
glands have been
tightened.
K2 Limit and Test 1. Functional test of the 1. Repair/troubleshoot Annually
Pressure limit switch by the limit switch if
Switches opening the doors of possible. Replace if
the agent release not.
cabinet or the cylinder 2. Repair/troubleshoot
enclosure and the pressure switch if
checking that all the possible. Replace if
alarms are activated not.
as per design (see Contact Archer for
document: ARC-AKS- more details.
LP-WS-01). Ensure
that all personnel in
the protected area are
aware of the testing.
2. Functional test of the
pressure switch by
removing it from the
distribution pipe and
connecting it to a test
manifold to be
pressurizing using an
external pressure
source (e.g
compressed air) at 20
bar. Ensure that all
personnel in the
protected area are
aware of the testing.

L1 Agent Inspection 1. The doors and 1. Repair parts that are Annually
release cabinet should be damaged (hinges,
cabinet inspected for signs of handles etc.)
corrosion and 2. If paint is found
physical damage. missing or chipped in
2. Check condition of places, apply paint
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paint. (this should be
3. Check that the key marine grade paint
box along with the minimum) to the
key is in place. affected area.
4. Check that there are 3. Replace key if found
no unrelated items missing.
stored inside the 4. Remove unrelated
cabinet. items in the cabinet.
5. Check that the valves 5. Replace valve if
are in good condition. found
Isolate the relay box faulty/damaged.
before inspection.
L2 Agent Maintenance 1. Exercise and lubricate Replace slow leak valve Semi-Annually
release the valves. if found corroded or
cabinet 2. Check the slow leak physically damaged.
valves for signs of
corrosion and
physical damage.
Isolate the relay box
before inspection.
M1 Discharge/ Inspection 1. Check the hose 1. Replace the hoses if Annually
pilot hoses fittings for corrosion found corroded or
and physical damage. physically
2. Check the hose for damaged/cuts.
cuts.
Isolate the relay box
before inspection.
M2 Discharge/ Testing 1. Hoses are to be 1. If hoses are found 5 years
pilot hoses pressure tested with leaking, please
water to 1.5 times the replace the hoses.
nominal pressure Contact archer for
(200bar at 25⁰C). more details.
Pressure test to be
done only by
authorized agent.
Certificates to be
issued.
Isolate the relay box
before inspection.
N Check Inspection 1. Check the check 1. Replace the check Annually
valves valves for signs of valve if corroded or
corrosion and physically damaged.
physical damage.
Isolate the relay box
before inspection.
O1 Cylinder Inspection 1. The doors and 1. Repair parts that are Annually
enclosure enclosure should be damaged (hinges,
inspected for signs of handles etc.)
corrosion and 2. If paint is found
physical damage. missing or chipped in
2. Check condition of places, apply paint
paint. (this should be
3. Check that there are marine grade paint
no unrelated items minimum) to the
stored inside the affected area.
cabinet. 3. Remove unrelated
Isolate the relay box items in the cabinet.
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before inspection.
O2 Cylinder Maintenance 1. Exercise and lubricate 1. Replace hinges if Quarterly
Enclosure the door hinges. found faulty.
2. Check for sign of 2. Repair the damaged
corrosion and as necessary.
physical damage to
the enclosure.
Isolate the relay box
before inspection.

Note
The control panel and limit
switches must be disabled
before any work is carried
out on the system.

O3 Cylinder Test 1. Inspect for any signs 1. Repair as necessary Annually.

Enclosure off leakage or or contact Archer for
damage that affect more details.
the IP55 rating of the
enclosure.

Isolate the relay box

before inspection.
P1 Relay Box Inspection 1. The doors and box 1. Repair parts that are Semi-Annually
should be inspected damaged (hinges,
for signs of corrosion handles etc.)
and physical damage. 2. If paint is found
2. Check condition of missing or chipped in
paint. places, apply paint
3. Check that there are (this should be
no additional marine grade paint
electrical components minimum) to the
installed inside the affected area.
box as this would 3. Remove unrelated
violate the EX’d rating items in the box.
of the relay box.
P2 Relay Box Maintenance 1. Exercise and lubricate 1. Replace hinges if Quarterly
the door hinges and found faulty.
at the door opening.
P3 Relay Box Test 1. Test the electrical 1. Semi-Annually
power supply back up
by disconnecting the
main supply and
confirming that the
AC LED at the front
door stays on.
2. Check all relays and
terminal blocks are in
securely mounted and
in good physical
condition.
Q1 Alarm Inspection 2. Check that the alarm 1. Remount the Semi-Annually
Beacons beacon sounders in sounders if
Sounders the protected spaces necessary.
are in good physical 2. Replace the
condition. sounders if found
damaged.
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Q2 Alarm Test 1. Check that the 1. Troubleshoot the Annually
Beacons sounders sounding sounders cable
Sounders can be heard by wiring if found faulty.
opening the release 2. Replace the
cabinet. Ensure that sounders if found
the personnel in the damaged.
protected space is
aware while testing
the system.
R Orifice Inspection 1. Check that the orifice 1. Replace the orifice Annually
plate plate is in good plate if corroded or
physical condition and damaged.
not corroded.
2. Check that the orifice
plates are clear and
unobstructed.
Isolate the relay box
before inspection.
S Safety Inspection 1. Check that the safety 1. Replace the safety Annually
Relief valve relief valve is in good relief valve if found
physical condition and damaged or
not corroded. corroded.
2. Check that the NPT 2. Repair the thread if
thread to the pipe is in necessary.
good condition.
Isolate the relay box
before inspection.
T1 Manifold Inspection 1. Check that the 1. Replace the pressure Semi-Annually
Pressure manifold pressure gauge if the found
gauge gauge is in good faulty/damaged.
physical condition and 2.
not corroded.
Isolate the relay box
before inspection.
T2 Manifold Testing 1. Disconnect the 3. Replace the pressure Semi-Annually
Pressure manifold pressure gauge if the found
gauge gauge from the faulty/damaged.
manifold. Connect it 4.
to an external
pressure source and
test it at nominal
pressure of 200bar.
Check if it shows the
correct reading.
Isolate the relay box
before inspection.
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2. ANNUAL SYSTEM TEST

Important: Ensure all unnecessary personnel evacuated from areas (e.g IG-541 Storage and Protected
rooms) where the system test is carried out, and all concerned are notified before proceeding with the
system test.

 Check that system documentation is available.

 IG-541 nozzles are correctly installed at locations as per drawing (ARC-AKS-LP-PL-01&02) of
the respective protected space.
 Availability of power supply to IG-541 connection box.
 Ensure sounding of IG-541 alarms upon opening of release cabinet (ARC-AKS-LP-WS-01).
 Check the pressure switch activation at 20bar. (if applicable)

3. IG-541 MAIN/RESERVE CHANGEOVER INTRUCTIONS

After System Discharge:

The main cylinders should be removed and sent to an authorized fill station for cylinder recharge. The system
should be transferred to the reserve cylinders until the main cylinders have completed recharging.

The following procedure is applicable if (any of the below):

 Main system is found to be faulty.
 There is a false discharge.
 The gas suppression system has been operated due to fire, but it is necessary to reinstate the
equipment in the protected space back into operation.

Warning: The following procedures are to be carried out at the owner’s own risk. In normal
circumstances, it is advisable to engage an authorized installer to perform the switchover.

Note: In some cases, it is only necessary to replace one or two cylinders that have been found to be
damaged or faulty. In this case, it is of course only necessary to replace the cylinders, and not move all
components to the reserve manifold.

1. Remove the manual/pneumatic actuators, pneumatic actuators, discharge hoses, pilot hoses/lines,
manifold check valves, multiple space assembly from the main cylinders.
2. Inspect the manual/pneumatic actuators to ensure it is in good condition and free to operate. Ensure it
is fully RESET before installation.
3. Inspect the pneumatic actuators and ensure it is in good condition and free to operate. Ensure it is fully
RESET before installation.
4. Inspect the discharge hoses and pilot hoses to ensure that they are clear of blockages and in good
condition.
5. Inspect the manifold check valves and multiple space assembly for correct direction before installation.
6. Connect the manual/pneumatic actuators, pneumatic actuators, discharge hoses, pilot hoses/lines,
manifold check valves, multiple space assembly to the reserve IG-541 cylinders in accordance to
manufacturer’s instructions (See table 1.0).
7. The CO2 pilot cylinder in the release cabinet will either be replaced or removed after operation (see
below)
 Once done, please do the following to check for the system to be commission and online
a. Reset the selector valve to closed position in IG-541 room
b. Ensure all discharge hoses on manifold connected to cylinder valves.
c. All instruction plates and indicating signs are in correct positions.
d. All CO2 release cabinet pilot lines connected back to pilot cylinder.
e. Remove SAFETY PINS on manual/pneumatic actuators.
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Table 1.0

S/N ITEM INSTALLATION PROCEDURE Remarks

REF:
1. Manual/Pneumatic Actuator ARC-AKS-LP-GA-02 Detail G NA
2. Pneumatic Actuator ARC-AKS-LP-GA-02 Detail G NA
3. Discharge hoses ARC-AKS-LP-GA-02 Detail C NA
4. Pilot hoses ARC-AKS-LP-GA-02 Detail C NA
5. Manifold check valves ARC-AKS-LP-GA-02 Detail C NA
6. Multiple space assembly ARC-AKS-LP-GA-02 Detail E & F NA

4. REMOVING IG-541 CYLINDERS FOR RECHARGING

The cylinders should only be recharged by an authorized vendor. Contact Archer for more details.

a. Release any residual pressure in the pilot hoses by slowly slightly opening the connection nut at the
valve. Let the pressure relieve fully before undoing the hose nut.
b. Remove the pneumatic/manual actuator from each valve.
c. Remove the discharge hose from the valve and fit the valve outlet cap.
d. Fit the valve cap and remove the cylinders from the racking.

5. RECHARGING CO2 PILOT CYLINDER

The cylinders should only be recharged by an authorized vendor. Contact Archer for more details.

a. Ensure that the 2 ball valves pilot line located in the release cabinet is in closed position.
b. Tighten the empty pilot cylinder by turning the wheel at the top of the pilot cylinder.
c. Remove both of the pilot tubing located at the bottom of the release cabinet to avoid accidental
discharge.
d. Release any residual pressure in the pilot line by slowly opening the connection nut connecting to the
empty pilot cylinder located within the release cabinet. Let the pressure relieve fully before undoing fully
the connection nut of the empty pilot cylinder.
e. Remove the CO2 pilot cylinder from the release cabinet.
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6. PRESSURE/TEMPERATURE GRAPH FOR IG-541 SYSTEM

Figure 2
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This document explains the operational features of the system, and serves as a guideline
for the safety officer to develop and implement a detailED emergency response plan.
These operational instructions do not preclude those of the owner or the authority having
jurisdiction. All personnel (temporary or permanent) working in the area should be
trained on the operation of this system. All personnel need to be aware of the alarm tones
of the gas suppression system, and the location of the manual release cabinets.

The purpose of this document is to provide the safety officer with basic instruction to
develop and implement a detail emergency response plan. For more information on
system operation, please do not hesitate to contact Archer (s) Pte Ltd.

1.0. OPERATION INSTRUCTION

Each manual release cabinet has an operational chart mounted on the panel door. See figure 2.0

1. IN THE EVENT OF EMERGENCY:

a) Ensure that the protected space is evacuated.

b) Proceed to the manual release cabinet located outside of the exit to the protected space.
This manual release cabinet will be labeled with the location of the protected space (see
figure 2.0)
c) Break key box next to the manual release cabinet to reach key. Open manual release
cabinet. This will trigger a LIMIT SWITCH which activates all alarms inside the protected
spaces.
d) Open any one of the pilot cylinder valves. The line is now pressurized and the pressure
gage level should indicate ~ 40 to 55 bar. If there is no pressure, then open the reserve pilot
cylinder. (see figure 5.0)
e) Pull the ball valve on the right upwards (see figure 5.0). This actuates the selector valve
that leads to the protected spaces.
f) Pull the ball valve on the left downwards (see figure 5.0). This actuates the main cylinder
valve. The time delay unit generates a 30s – 45s delay before actuation of the IG-541
cylinder.
g) Gas is now discharged.
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2.0. OPERATION CHART FOR MANUAL RELEASE CABINET

IG-541 FIRE EXTINGUISHING SYSTEM

RELEASE CABINET
SWITCHGEAR ROOM

INSTRUCTIONS
1 EVACUATE THE PROTECTED SPACE

2 CLOSE ALL DOORS AND OPENINGS

3 TURN RIGHT LEVER UP

4 TURN LEFT LEVER DOWN

5 OPEN SCREW DOWN VALVE ON CO2 CYLINDER

6 SYSTEM IS NOW OPERATED

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3.0. EMERGENCY OPERATION INSTRUCTION

Note: This operation will override the time delay function.

Please ensure all personnel are evacuated from the protected area before operation of
the system.

1. IN THE EVENT OF EMERGENCY:

a) Proceed to the cabinet/enclosure where the IG-541 agent cylinder is.

b) Open the door of the cabinet/enclosure. This will activate all alarms inside the protected
spaces.
c) Go to the selector valve showing the protected space location.
d) Turn the handle down to actuate the selector valve.
e) Proceed to the IG-541 cylinder which indicates the location of the protected space.
f) Turn the manual pneumatic actuator located at the top of the IG-541 cylinder valve. This
will actuate the IG-541 into the protected spaces.
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4.0. OPERATION CHART FOR THE IG-541 ENCLOSURE/CABINET

IG-541 FIRE EXTINGUISHING SYSTEM

EMERGENCY OPERATION
Note: This operation will override the time delay function .
INSTRUCTION
1 ENSURE ALL PERSONNEL HAVE EVACUATED THE PROTECTED
SPACE.

2 CLOSE ALL DOORS AND OPENINGS.

3 GO TO THE SELECTOR VALVE FOR THE PROTECTED SPACES.

4 TURN DOWN THE MANUAL/PNEUMATIC ACTUATOR HANDLE

LOCATED AT THE TOP OF THE SELECTOR VALVE.
5 GO TO THE IG-541 AGENT CYLINDERS SHOWING THE
PROTECTED SPACES.

6 PULL DOWN THE MANUAL/PNEUMATIC ACTUATOR HANDLE

LOCATED AT THE TOP OF THE IG-541 AGENTCYLINDERS
VALVES.

7 SYSTEM IS NOW OPERATED

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5.0. Drawing of the manual release cabinet