BS 60080-2020
BS 60080-2020
60080:2020
The BSI copyright notice displayed in this document indicates when the document was last issued.
ICS 29.260.20
Contents Page
Foreword iv
0 Introduction 1
0.1 General 1
0.2 Document structure 1
Figure 1 — Document structure 2
1 Scope 2
2 Normative references 3
3 Terms and definitions 3
4 Hazard identification and risk assessment 5
Figure 2 — Risk assessment process 6
5 Fire and gas (F&G) philosophy 7
5.1 General 7
5.2 Detector location – practical considerations 8
5.3 Brownfield versus greenfield considerations 8
6 Detection technology 9
6.1 General 9
6.2 Flame detection 9
Figure 3 — Typical point of view (POV) alongside external view of the same envelope 10
Figure 4 — Example of a flame detector field of view 10
6.3 Heat detection 12
6.4 Flammable gas detection 12
6.5 Toxic gas detection 13
6.6 Ultrasonic (acoustic) gas leak detectors 14
7 F&G mapping techniques 14
7.1 General 14
7.2 Flame properties 14
7.3 Flame detection 16
Figure 5 — Example of a single flame detector map shown in 3D and 2D views 16
Figure 6 — Chessboard analogy and percentage coverage 20
7.4 Fluid states and dispersion 21
Figure 7 — Jet entrainment 23
7.5 Flammable gas detection 24
Figure 8 — Example detection output 31
Figure 9 — Detector contributions analysis 32
Figure 10 — Relationship between scenarios considered and percentage of scenarios detected 33
7.6 Toxic gas detection 36
Figure 11 — Response time with a steady release of toxic gas 38
Table 1 — Factors in risk and mitigation 39
8 Detailed engineering 47
8.1 General 47
8.2 Schedule constraints 47
8.3 Management of change 48
Figure 12 — Example of ventilation analysis 49
8.4 Human factors and ergonomics 49
9 Installation and commissioning (verification) 49
9.1 Planning 49
9.2 Execution 50
10 System validation 51
10.1 Planning 51
10.2 System validation test 51
11 Operation, maintenance and modification 52
11.1 Evergreening 52
11.2 Planning 52
11.3 F&G detection system – execution 53
11.4 Maintenance 53
11.5 Modification (management of change) 54
12 Competence 55
Annex A (informative) Oxygen enrichment and deficiency 56
Annex B (informative) Flame detection – Example of volumetric-based mapping 58
Table B.1 — Flame detection performance targets 58
Figure B.1 — Volume to be mapped 58
Figure B.2 — Grademap volume 59
Figure B.3 — Risk grade map 59
Figure B.4 — Existing devices coverage map 60
Figure B.5 — Existing flame detectors (coverage 1 of 2) 60
Figure B.6 — Existing flame detectors (coverage 2 of 2) 61
Figure B.7 — Proposed additional flame detector 61
Figure B.8 — Updated assessment coverage map (1 of 2) 62
Figure B.9 — Updated assessment coverage map (2 of 2) 62
Figure B.10 — Example of basic 2D representation of one detector 63
Figure B.11 — Example of 2D plane of one detector through a 3D model 64
Figure B.12 — Example of basic 2D representation of two detectors 65
Figure B.13 — Example of two detectors through a 3D model 66
Figure B.14 — Example of basic 2D representation of three detectors 67
Figure B.15 — Example of 2D plane of three detectors through a 3D model 68
Annex C (informative) Flammable gas detection – Volumetric-based mapping 69
Table C.1 — Estimated blockage ratio 69
Table C.2 — Flammable gas detection performance targets 69
Figure C.1 — Volume to be mapped 70
Figure C.2 — Grademap volume 70
Figure C.3 — Risk grade map 70
Figure C.4 — Existing gas detectors 71
Figure C.5 — Existing devices coverage map (1 of 2) 71
Figure C.6 — Existing devices coverage map (2 of 2) 72
Figure C.7 — Updated detection layout 72
Figure C.8 — Updated assessment coverage map (1 of 2) 73
Figure C.9 — Updated assessment coverage map (2 of 2) 73
Figure C.10 — Exampe of OPGD placement in a 3D model 74
Annex D (informative) Risk and mitigation identification 75
Table D.1 — Example of facility information 75
Table D.2 — Example performance targets 78
Figure D.1 — Example of facility requirements grade map 79
Annex E (informative) Graphic symbols for fire and gas detection location drawings 80
Table E.1 — Graphical symbols 81
Bibliography 84
Summary of pages
This document comprises a front cover, and inside front cover, pages i to iv, pages 1 to 86, an inside back cover and
a back cover.
Foreword
Publishing information
This British Standard is published by BSI Standards Limited, under licence from The British
Standards Institution, and came into effect on 30 September 2020. It was prepared by subcommittee
EXL/31/1, Gas detectors, under the authority of Technical Committee EXL/31, Equipment for explosive
atmospheres. A list of organizations represented on these committees can be obtained on request to
their committee managers.
Presentational conventions
The provisions of this standard are presented in roman (i.e. upright) type. Its requirements are
expressed in sentences in which the principal auxiliary verb is “shall”.
Commentary, explanation and general informative material is presented in smaller italic type, and does
not constitute a normative element.
Where words have alternative spellings, the preferred spelling of the Shorter Oxford English
Dictionary is used (e.g. “organization” rather than “organisation”).
0 Introduction
0.1 General
This British Standard is written in the form of guidance and supports flame and gas (F&G) detection
standards across the industry.
One of the most challenging activities faced by a design engineer is deciding the quantity and location
of gas detectors and/or flame detectors.
This British Standard refers to F&G coverage factors but does not specify target coverage factors for
different applications. Coverage factors are only broad targets and are easily manipulated by changing
device sensitivities, alarm trip levels, voting configurations, target gas concentrations, target flame
size and other factors.
This British Standard also provides guidance on sensing technologies and the physical format of
detectors which could greatly affect coverage (quantity and position). Irrespective of the quantity and
positioning of detectors by a manual or software-related activity, the selection of incorrect sensing
technologies leads to incidents not being detected or an increase in spurious trips.
This British Standard provides guidance on the full life cycle of a gas detection or flame detection
system, emphasizing that mapping and/or modelling is an ongoing activity and not simply an activity
that is carried out once in the design of a new facility. Routine surveillance of detector coverage
during the full life cycle of a facility ensures that facility modification, changes in hazards, etc.,
are all addressed, and the management of change highlights any deficiencies or opportunities for
improvement.
Detector coverage within this British Standard means permanently-installed devices, which are the
only devices for which guidance is provided. The use of additional personal monitors, e.g. portable
gas detectors, does theoretically increase the density of “detecting devices” when persons are actively
working within a plant area or location.
This British Standard is based on existing and established sensing and detector technologies and
configurations. It is also based on many years of industrial experiences and lessons learned. This
British Standard does not exclude emerging technologies or innovative ideas; however unless there
is reasonable and practical evidence that these technologies or methodologies offer equal benefits,
caution is advised.
This British Standard provides informative guidance on detection symbols (see Annex E), however
this guidance does not preclude continued application of any established symbols applied by an
operator or designer.
1 Scope
This British Standard provides guidance on the placement of permanently-installed F&G detectors,
including coverage and technology selection.
NOTE 1 “Permanently-installed detection systems” include optical flame detection (including ultraviolet, infrared
and imaging/visual), flammable gas/vapour detection and toxic gas detection.
This British Standard provides guidance on the most commonly used methods of mapping and/or
modelling: prescriptive, volumetric-based and scenario-based.
This British Standard is applicable to applications where:
a) optical flame detection is used as a means of detecting flaming fires in internal and external
environments;
b) a gas detection system is used as a method of explosion protection;
c) the hazard arises from the release or accumulation of explosive gases and vapours; and
d) the hazard arises from the release or accumulation of toxic gases.
This British Standard also provides guidance on operations, maintenance and the availability/
reliability of the system to complement relevant standards.
This British Standard does not provide guidance for:
1) addressing hazards that are a product of vehicle exhaust fumes;
2) applications in the domestic and general public environment;
3) applications in mining and tunnelling, heating ventilation and air conditioning (HVAC), medical
applications or environments;
4) smoke detection; or
5) toxic gas detection with regard to business continuity, e.g. food tainting.
Mitigation effectiveness is an important aspect of F&G detection design but is out of scope of this
British Standard.
NOTE 2 Oxygen detection is typically biased towards prescriptive methods for detector coverage and is generally
excluded from this British Standard, considerations regarding typical oxygen detection are described in Annex A.
2 Normative references
There are no normative references in this British Standard.
3.3 consequence
qualification/quantification of the harm caused by a hazard
NOTE Examples include death, injury, escalation.
3.4 coverage
criteria by which the volume/scenario is monitored or unmonitored with respect to detection success
NOTE Coverage can be represented as a percentage calculation, visual representation or both.
3.14 hazard
source that has the potential to cause harm to someone or something
3.24 risk
combination of the frequency/likelihood of harm occurring and the consequence severity
A typical risk assessment process is shown in Figure 2 with the objective of determining if adequate
control measures are in place so that risks can be deemed As Low As Reasonably Practicable
(ALARP). For flammable gases and vapours, this process is typically conducted as part of a Dangerous
Substances and Explosive Atmospheres Regulations 2002 (DSEAR) [2] assessment. For toxic gases
and vapours this is often carried out as part of a the Control of Substances Hazardous to Health
Regulations 2002 (COSHH) [3] assessment.
One control measure is flame and/or gas (flammable and toxic) detection. In most cases F&G
detection only detects the hazard rather than preventing the hazard and offers limited benefit in
terms of reducing the potential for immediate fatalities. It is when combined with additional risk
reduction measures (e.g. blowdown, deluge, alarms) that consequence and hence risk is lowered by
reducing the potential for escalation. The F&G detection system is classed as mitigation when the
centre of the bowtie is the release of flammable/toxic materials, or a fire.
NOTE 2 For further information on bowtie, see https://www.gov.uk/government/news/bowtie-a-visual-tool-to-
keep-an-overview-of-risk-management-practices.
The risk assessment process can range from qualitative to fully quantitative and the level of effort
should be proportional to the risk; a concept known as proportionality. For example, it is not
necessary to conduct a fully quantitative study if determining the flammable risk arising from an
isolated single flammable source (e.g. propane bottle) in an unmanned room. This British Standard
assumes that a risk assessment has been conducted with the output being that flame and/or gas
detection is required to demonstrate that risks are ALARP. This British Standard provides guidance
on the process to justify the number of detectors to employ and where to put them.
Toxic gas detection introduces different layers of complexity compared to flame and flammable gas.
For flame and flammable gas, the risk assessment process identifies any requirement for fixed flame/
gas detection and the detector location requirement is based on the required control measures
in place to mitigate the event of a fire/flammable gas release. For toxic gas, the risk assessment
identifies the requirement for fixed detection and informs the decision on how many detectors are
required and their location. It is therefore necessary to take account of the other control measures
that are in place, along with the desired outcome of detection with respect to toxicity, when making
the decision on positioning requirements for toxics. Further guidance on other control measures and
how they affect decisions on the location and number of detectors is given in 7.6.
c) the mapping zones, including the methodology used to define them, if not included within the
company’s internal guidance document;
d) area grading rules (if applicable) that define the performance criteria based on different
assessed risk categories (see 7.3.2, 7.5.2, 7.6.2);
e) what technologies are appropriate for the environment and hazard;
f) set points and voting requirements for detectors; and
g) whether there are multiple design authorities/certification bodies/stakeholders for a particular
installation/site, e.g. for a floating production storage and offloading (FPSO) installation the
certification body would differ between the hull and topsides. Ideally a single consistent
philosophy should be developed for the installation but if this is not possible it might be
necessary to include details of how the philosophy differs across the installation/site and how
the interfaces are managed.
The mapping methods to be applied could differ as the design progresses. More detailed methods
might not be appropriate early on in a design as sufficient information might not be available.
5.2.2 Mounting
Once positioning has been determined by a mapping study, correct mounting becomes important
for the correct operation of devices. Detector mounts should be permanently secured to structural
steelwork, where practicable. Where mounting posts are to be used, consultation with the civil
engineer might be necessary to determine the suitability of locations, e.g. taking account of drainage
channels where mounting foundations might not be possible.
An apparent “optimum” mapping result which requires multiple detectors in a zone to be moved
is typically more expensive to engineer than purchase and installation of an additional detector, so
an alternative solution involving the addition of a new detector to improve coverage might be more
cost‑efficient and practical.
Where this could present an issue, it is beneficial to agree an optimization policy prior to starting the
mapping exercise, typically based on overall cost efficiency and effectiveness rather than a simple
metric of total detector numbers, to achieve the desired coverage or risk reduction target.
An example would be a brownfield policy for flame detection optimization making changes to the
layout, where necessary to close gaps or meet targets, in the following order of preference.
a) Change angles/orientations of flame detectors.
b) Consider making one or two small moves (preferably within the cable slack).
c) If target still not met, consider adding new detectors in new locations rather than multiple
relocations of existing detectors.
Consideration of risk reduction to ALARP is particularly relevant when justifying addition of new
detection in brownfield studies, as practicability of implementation is a significant issue.
6 Detection technology
6.1 General
For all types of detection, the detector technology selected needs to be suitable for the hazard types
which might be present in the particular location, e.g.:
a) if there is a risk of a unique fuel (i.e. hydrogen), it is important to be aware of the fire detector
types and capability; and
b) certain flammable vapours, such as benzene, are not detected by standard infrared line of site
(IR LOS) detection.
Interoperability between device and system could have an impact on device selection. This should
be taken into account as early as possible in the design philosophy. If this information is not
available, conservative assumptions should be made with respect to coverage and updated as the
project evolves.
Figure 3 — Typical point of view (POV) alongside external view of the same envelope
This information is typically included in the detector technical manual and should be used, if possible,
to define the volume of coverage in the mapping software.
An example of how this is characterized in one software package is shown in Figure 4. In this case,
the inner and outer envelopes represent the detection ranges for two sensitivity settings, as set by
detector hardware switches.
Figure 4 — Example of a flame detector field of view
As each detector model has a different detection envelope, it is important to model the correct
detector type. Optical flame detector mapping should include the following information to model the
coverage characteristic:
a) detector make and model;
b) detector sensitivity setting; and
c) fuel (for the fire hazard being modelled).
The mapping methodology should also take account of degraded performance in operational
conditions, e.g. by factoring in a reduced detection distance to allow for dirty optics. Where the
detector manufacturer does not publish sensitivity distances for the precise fuel type, the nearest one
should be selected (see 7.2.4 for guidance on spectral characteristics).
Detector sensitivity is not a standardized parameter with flame detection. Flame detector
manufacturers publish performance claims to a set of tested fires. Performance of the device in the
field is determined against these, typically using the inverse square law. This means a fixed detection
cone is rarely an acceptable way of modelling coverage as the device might be able to see a fire at a
much greater distance if the radiant heat output (RHO) of the flame is sufficiently high.
For example, a square foot n-Heptane pan fire is widely accepted to generate an RHO of
approximately 40 kW. If the data sheet claims detection of this fire at 30 m, it can be modelled that the
flame detector detects a 160 kW fire at 60 m (see 7.3.7.1 for guidance on the inverse square law).
6.4.2 Pellistor
The pellistor sensor works on a Wheatsone bridge principle where one of the four resistors react
to the target gas. This chemical reaction results in a rising temperature that causes an electrical
change across the bridge. Certain airborne contaminants can affect the chemical reaction on a
temporary or permanent basis, so regular maintenance is a supporting requirement when using
pellistor technology.
NOTE Pellistor is also referred to as catalytic.
6.4.5.1 IR based
IR LOS detectors transmit an IR beam between a transmitter and a receiver. LOS detectors can have
a path length between 0 m and 250 m and the maximum allowable path length should be taken
into account.
IR devices might show a differing response to lower explosive limit (LEL) levels of different gases
and devices need to be selected to detect all hazardous gases within the target zone and the alarm
set point selected to ensure adequate response to the least sensitive gas likely to be encountered in a
hazardous situation.
LOS detectors measure the integrated gas concentration within the beam path (beam path
absorption), e.g. if a well‑mixed gas/air accumulation of 10% LEL concentration was enclosed and
fully distributed throughout a module in which the following LOS detectors were installed, the
following signals would be recorded from each device:
a) LOS 1: 10 m long would record 10 m × 10% LEL = 100% LEL m or 1 LEL m; and
b) LOS 2: 30 m long would record 30 m × 10% LEL = 300% LEL m or 3 LEL m.
of optical-based flame detection should be determined. In determining the risk posed by such flaming
hazards, a number of factors should be taken into account, including, but not limited to, the:
a) nature of the anticipated fire (gas jet, liquid spray, pool fire, etc.) (see 7.2.2 and 7.2.3);
b) burning characteristics of the material in the area (whether the processed material contains
materials which burn with a unique characteristic making detection through optical means
difficult, e.g. hydrogen) (see 7.2.4);
c) escalation potential of a secondary fire, such as escalation potential associated with a particular
piece of equipment or area, e.g. if a 100 kW RHO flame impinges a particular vessel, is there
potential for escalation which would be unacceptable against the organization’s risk philosophy,
e.g. boiling liquid expanding vapour explosion (BLEVE);
d) dimensions of the graded volume for a piece of equipment [e.g. at what distance from a vessel
would the target fire (e.g. 100 kW) not lead to escalation]; and
e) fire load/inventory size, e.g. fire duration.
Accounting for the factors in a) to e) allows the designer to apply escalation grades/performance
targets (see 7.3.2) when prescriptive measures are not applied.
7.2.5 Environment
The environment in which optical flame detectors are to be applied should be taken into account,
including seasonal weather conditions, e.g. will the detector operate in warm/cold temperatures,
when there is fog/mist, when the sun is shining/modulating?
a) 3D view b) 2D view
and FM 3260 [4]). RHO provides a good indication of the potential damage and likelihood of
escalation and loss.
NOTE 1 When applying RHO as a metric, the designer is required to implement an RHO value for the type of fire
specified. There is no industry consensus or standard which specifies how to do this, but methods include extracting
values from test burns, fire models, traditional fire dynamics calculations, etc.
Grades and performance standards should avoid using target fires which flame detectors have not
been certified to detect (i.e. large fires which result in sensor saturation/blinding). The target fire
sizes used in the placement of flame detectors are typically smaller than those associated with
escalation, i.e. the intention is to detect the fire before escalation occurs, not to detect the fire which
could credibly occur in a worst-case scenario. Care should be taken if determining the placement
of flame detectors based on worst-case fires calculated as part of the predictive aspects of a Control
of Major Accident Hazards Regulations 1999 (COMAH) [5] assessment or a fire risk assessment/
quantitative risk assessment (QRA) conducted to support an offshore safety case. If detectors are
located on this basis, smaller fires that could potentially cause escalation might not be detected, and
the design could be based on fires the detectors are not certified or capable of detecting.
Multiple target fire sizes are often taken into account, including:
a) target fire size for alarm (where the fire is not significant enough to result in automated actions
and can be dealt with manually); and
b) target fire size for executive action (when an operator can no longer be relied upon to initiate the
mitigating action manually to reduce/prevent escalation, i.e. the fire has grown to a level where
automated action is required).
These fire sizes have different values (based on RHO), e.g. an alarm is generated at 50 kW RHO fire
and executive action at 100 kW RHO.
Where the escalation potential and methodology warrant it, graded volumes can be defined within
the mapping zone. The size of the fire to be detected within the graded volume can be based on
the escalation potential, if that fire occurs within that volume, allowing optimization of the layout,
i.e. smaller fires can be targeted for high escalation areas.
Where the escalation potential and method warrant the application of graded volumes,
representation should allow for presentation of coverage beyond a binary “coverage” or “no
coverage” (e.g. a fixed XX m detection cone is rarely a suitable metric of coverage). To design a
performance-based flame detection system based on a review of escalation potential there are
multiple factors to take into account, including but not limited to percentage coverage of:
1) alarm only;
2) control action;
3) late alarm; and
4) minimal coverage to all target fire sizes.
NOTE 2 “Late alarm” represents a location where the target fire size for control action will be detected by two
devices, however any smaller target fire size for alarm will not be detected to provide a fast response alarm without
executive actions.
NOTE 3 ”Minimal” coverage represents a location where the target fire size is not within range, but if it grows
beyond the specified target, it will be detected by a single device (1ooN) as a clear line of sight exists to that point.
7.3.3 Prescriptive
Prescriptive flame detector mapping refers to the use of qualitative evaluation and judgement-based
placement in the locating of flame detectors. Examples include:
a) proven design that is reused for similar applications; in many instances this would not require a
full modelling activity;
b) prescriptive ruleset provided by the operator; compliance can be verified using a checkbox type
review to ensure the rules are met; and
c) for open facilities with minimal obstruction to the field of view, it might be sufficient to
place detectors at the extremities of the area where fires could exist, taking account of the
detector range.
Software flame and gas modelling tools and metrics (e.g. fire size/percentage coverage) are not
required when using the prescriptive approach and compliance can often be checked using a
checkbox-type approach against the rule set that has been employed.
Key
Not covered
Covered
Coverage represented using the point source approach requires a clear line of sight to the location of
the targeted fire to be represented as successful detection. Engineering judgement is then applied to
analyse adequacy of the layout and subsequent coverage (see 7.3.6).
Care should be taken when using volume source modelling as the result could differ depending upon
flame detection technologies and/or models (e.g. the region of the electromagnetic spectrum the
device operates, specific filters applied, signal processing firmware, burning fuel).
EXAMPLE Two “triple IR” flame detectors, despite being the same technology, might use different
filters along the mid IR range (impacting solar blindness, sensitivity, false alarm immunity, etc.),
analysing the signals received in a unique way. Where the flame volume is partially obscured by
geometry, the features of the specific flame detector being modelled (including sensitivity to the
portion of the flame visible, the environmental conditions of the facility and any desensitization the
flame detector might be subjected to) should be taken into account.
NOTE These data are often protected by the flame detector manufacturer.
gas/vapour accumulates and hence where detectors are placed. This is equally applicable to both
flammables and toxic gasses. The different physical states are:
a) a gas, which might be at an elevated temperature or pressure;
b) a gas liquefied by the application of pressure, e.g. LPG, CO2;
c) a gas which can only be liquefied by refrigeration, e.g. methane; and
d) a liquid with an associated release of flammable or toxic vapour.
In addition to fluid state, ventilation also affects where gas accumulates and how gas/vapour
disperses to a safe limit (i.e. below the flammable or toxic limits). The different types of
ventilation are:
1) local extract ventilation;
NOTE 1 This is generally installed local to a release point to remove gas/vapour and exhaust it to a
safe location.
3) natural ventilation;
NOTE 3 For enclosed plants, natural ventilation is provided by either flow-through louvres or advantageous
openings around doors, windows or penetrations.
For open plants, the degree of natural ventilation depends on external buildings (if significant), large items of
equipment, cladding and prevailing wind conditions.
With respect to natural ventilation and the placement of detectors, the greater the natural ventilation, the
more dilute the cloud and the “harder” it is to detect. Conversely, for a given release, the lower the consequence
as the flammable cloud is smaller. Therefore, for a plant that has significant ventilation, detection might be
impractical as it is unlikely to detect releases unless they are catastrophic.
Prior to detector mapping being carried out the nature of the release, ventilation and hazard range
should be determined. The hazard range can be used to inform the maximum distance from any
release point that detectors should be considered.
Accounting for the factors in 7.4.2 to 7.4.6 allows the designer to apply escalation grades/
performance targets where prescriptive measures are not applied.
For plumes, velocities are lower and therefore entrainment due to differential velocity is lower and
dispersion is governed by the bulk air flow (provided either naturally or via forced ventilation).
If releases impinge on geometry this reduces the momentum, and hence the velocity, leading to less
entrainment of air, larger cloud sizes and a break-up of the jet/plume type structure. If releases
are inside buildings, and the gas is not removed, there is the potential for gas to build up, leading
to a background concentration of gas; this leads to larger cloud sizes as air that is entrained into
the plume or jet already contains gas. Detectors should be placed in areas where gas is likely to
accumulate based on the geometry and/or room. The buoyancy of the gas also affects the size,
shape and location of where gas accumulates. Buoyancy tends to have more of an effect for plumes,
obstructed or internal releases. For unobstructed jets, the momentum and direction of the release
tends to dominate over any buoyancy affects.
would then absorb heat from the surroundings, leading to evaporation and the formation of vapour
that can add to the cloud formed from the aerosol.
“The gas detector should be set to alarm at a level low enough to ensure the health and safety
of people but high enough to prevent false alarms. False alarms are most likely to be caused by
fluctuations in sensor output due to environmental changes (e.g. ambient temperature, pressure
or humidity), sensitivity to other gases or vapours, or sensor drift. If false alarms are a problem
then one option is to use two detectors - the alarm level must be registered by both detectors
before the alarm activates.
"In determining the required alarm levels for fixed gas detection systems, the following should
be taken into account:
a) any industry standards and recommendations;
b) the LEL of the gas or vapour;
c) the size of the potential leak and the time to reach a hazardous situation;
d) whether the area is occupied;
e) the time required to respond to the alarm;
The set points to be used should be decided before the mapping is completed and should form part of
the gas mapping philosophy. This should be used as input if quantitative gas mapping (volumetric or
scenario-based method) is being carried out.
If quantitative gas mapping is carried out, sensitivity analysis could be performed to understand the
improvement in detection of using lower set points to understand the trade-off with the increased
potential for false alarms.
To minimize the potential for spurious trips within a mapping zone, detector voting can be employed.
As an example, an alarm would be generated if gas was detected by one detector (1ooN, where N is
the number of devices in the voting group) followed by an executive/control action on two detectors
detecting the gas (2ooN).
NOTE 3 Voting can also be applied when using multiple detectors at a specific point, e.g. 3 × smoke detectors
located within a vent duct.
Historically, detectors are perceived to be applied on (5 × 5) m spacing criteria based on HSE research
report, Report OTO 93 002 [8]. This research showed that the flame speed from a 6 m cloud would not
exceed 100 m/s and not produce overpressure of more than 150 mbarg for a methane or propane
cloud for a given geometrical configuration. Overpressures of this magnitude are lower than those
expected to lead to personnel fatalities.
NOTE See also HSE Technical Report SPC/Tech/OSD/30 [9].
The HSE research allowed for a moving scale of congestion/confinement changes which would
subsequently alter the targeted gas cloud size.
HSE research [9] can be used as a basis for detector spacing and risk-based target gas cloud size if
handling similar materials and looking to protect against personnel fatalities. If handling different
materials (e.g. hydrogen) or looking to protect against escalation (e.g. cloud size that would
not lead to failure of a blast wall or temporary refuge), a range of different approaches could be
used, including:
a) Qualitative:
The target cloud size to be detected is a function of:
1) the overpressure being protected against;
2) the material being handled;
3) congestion;
NOTE 1 Congestion increases the rate of combustion and hence overpressure as turbulence is generated
when the flame front interacts with geometry, increasing the rate at which combustion products are
mixed with unburnt fuel.
4) the confinement;
NOTE 2 Confinement is the degree to which the expansion of combustion products is inhibited by solid
boundaries, e.g. walls, decks or ceilings.
NOTE 3 A qualitative assessment would consider either the work by the HSE, other experimental work or
previous project experience to set a target cloud size based on a consideration of the parameters listed.
b) Semi-quantitative:
Semi-quantitative methods are defined as the use of empirical or phenomenological tools
to define a target gas cloud for a given overpressure, material, congestion and confinement.
Methods that could be employed are the multi-energy method and Game theory. Although
these methods are quantitative, they do not offer a rigorous determination of congestion and
confinement and the choice of the parameters used in these models can be subjective.
Use of the blockage ratio as a value, correlated to an anticipated explosion overpressure,
based on this congestion and confinement can also be applied to determine a target gas cloud
performance target.
c) Fully-quantitative:
Fully quantitative methods utilize computational fluid dynamics (CFD) explosion analysis to
quantify the target gas cloud size for a given overpressure in a specific area.
NOTE 4 CFD modelling in this context (explosion analysis) is not to be confused with CFD dispersion modelling
(traditional scenario-based probability analysis of dispersion characteristics).
CFD methods take 3D models of a facility (hence congestion and confinement are explicitly
included) and can capture the influence of the material being handled within the calculations. If
CFD modelling is to be employed, the influence of the following should be investigated, including:
1) Cloud position:
The location of the cloud with respect to congestion should be investigated (i.e. multiple
simulations should be run) to understand the influence on results.
2) Ignition location:
The influence of ignition location within the cloud should be investigated. In general, larger
overpressures are produced for ignition at the edge of a cloud as the flame has a greater
run-up distance through which to accelerate.
If CFD analysis is employed, multiple scenarios should be run and an appropriate target gas cloud size
selected based on the results. For example, it might not be appropriate to set the target gas cloud size
on the worst-case result if this far exceeds other scenarios modelled, and a more pragmatic approach
could be to choose an average of the modelled scenarios. If one scenario far exceeds the others
modelled it shows that this is based on a unique set of parameters (e.g. gas cloud in a particular
location and ignition location) which might be unlikely to occur. Care should be taken, however, in
applying such assumptions.
7.5.3 Prescriptive
Prescriptive flammable gas detector mapping refers to the use of qualitative evaluation and
judgement-based placement in the locating of gas detectors. Examples include:
a) proven design that is reused for similar applications;
b) ruleset-based approach, e.g. detectors at a spacing of X m; and
c) evaluation of the factors in 7.4 and detectors placed at locations where gas is likely to
accumulate; this is most appropriate for applications that do not contain many potential leak
sources and releases likely to behave in a predictable manner, e.g. no areas of recirculation.
Software modelling tools and metrics (e.g. target gas cloud size/percentage coverage) are not
required when applying the prescriptive approach; compliance can often be checked using a
checkbox-type approach against the ruleset that has been employed.
When conducting volumetric-based mapping, detector set points (see 7.5.1) can be accounted for
by scaling the target gas cloud by the dilution factor (e.g. low-level alarm based on cloud size of 15 m
and high-level alarm based on cloud size of 5 m); if consequence analysis has not been conducted this
factor has to be set based on designer judgement.
The following advantages and disadvantages are generated based on common applications where
the method is selected. The critical factor is use of the most appropriate methodology to the specific
application, e.g. the exclusion of subjective factors such as wind direction, leak orientation, gas release
rate., is a strength in the volumetric-based approach as it aims to detect dangerous accumulations
which could result in explosion, rather than calculate how this occurs. If the application is a
controlled environment, however, where variables are reduced (i.e. an internal volume with few
sources of release), the exclusion of those factors could be considered a disadvantage.
The advantage of volumetric-based mapping include:
a) 3D model can be applied for visualization purposes;
b) detailed information on process is not always required, e.g. heat and mass balance data;
c) subjective features of analysis are reduced by comparison with scenario-based mapping,
i.e. where leaks originate, likelihood of pipe rupture, etc.;
d) no complex modelling of specific scenarios is required;
e) analysis is relatively quick;
f) consistent designs;
g) easily audited;
h) coverage detects the “dangerous” accumulation of gas, with respect to explosion potential, with a
higher degree of certainty than alternative methods as it assumes accumulation has taken place
and aims to detect the critical cloud volume; and
i) change management is easily incorporated (i.e. detailed analysis does not need to be rerun as a
result of minor alterations in the process area).
The disadvantages of volumetric-based mapping include:
1) results can be influenced by the size of volume assessed;
2) there is no clear way of determining where the graded volume is to extend to;
3) subjective features of analysis are increased by comparison to prescriptive methods, i.e. various
cloud sizes, coverage adequacy interpretation, etc.; and
4) behaviour of releases might not be taken into account.
NOTE An example of volumetric-based gas mapping is given in Annex B.
a) 2D slice output
b) 3D volume output
Key
Control action
Alarm
No coverage
Figure 9 shows two example configurations against % coverage; the initially steeper gradient of the
darker shaded area (with diminishing returns around eight devices), maintains dominance over the
lighter shaded area until 11 detectors are added, for example.
When assessing the contribution of individual detectors and coverage of the volume, metrics
should not be reviewed in isolation as the nature of the area being covered should also be reviewed,
i.e. a given detector might be in an area with only limited congestion/confinement. Therefore, the
benefit of additional detectors should be reviewed in parallel with 2D or 3D results (see Figure 8)
to understand potential gaps in coverage, or areas where the system might be over-engineered.
This approach ensures the resultant design is suitably optimized by reviewing areas of suitable
coverage, blind spots where gas clouds might remain undetected, and how each detector contributes
to coverage for both 1ooN and 2ooN for both Hi and Lo alarm, where necessary. Reviewing detector
contributions allows the designer to analyse when the coverage is subject to diminishing returns for
the addition of more detectors.
NOTE The number of scenarios and percentage coverage in this figure are used for illustrative purposes only.
The number of scenarios required vary depending on the facility/installation in question. Factors that
would lead to more scenarios requiring analysis include:
a) number of release sources;
b) variance in process conditions, i.e. a greater range pressure, temperatures, fluid compositions
requiring more scenarios to be analysed;
c) variation of meteorological conditions, i.e. facilities with greater seasonal variance in
temperature or wind speeds/directions, require more scenarios to be analysed;
d) potential for wind “gusts”;
e) potential for the release to create freezing conditions at the orifice, resulting in changes to the
release trajectory; and
f) equipment size, i.e. if pipework is small bore the range of hole sizes to consider is lower.
Although scenario-based mapping and dispersion modelling considers representative releases,
simplifications are still made, and models are not validated for all conditions. The following should be
taken into account for the facility/installation being designed:
1) metrological conditions, e.g. wind speed, direction and temperature, are assumed to be constant
for a given scenario; and
2) many models are not validated for low wind speeds.
However, analysis such as that presented in Figure 10 cannot be compared to analysis of a volumetric
layout as in Figure 9, i.e. analysing the number of scenarios detected when detection is designed on a
volumetric basis. To compare the percentage of scenarios detected with the percentage of the volume
covered is misleading as the approaches are fundamentally opposed. A design which performs
strongly against one might perform poorly against the other.
should be defined (see 7.5.2). If detectors are placed solely on the results of probabilistic dispersion
analysis there is the potential to skew the detector coverage towards “small” releases as these are of
high likelihood but do not lead to adverse consequences.
Volumetric approaches typically focus on the response time of the gas detection devices (i.e. ensure
the target cloud is detected and the devices installed are of a sufficiently fast response), whereas
scenario-based method approaches can calculate the response time of the system from release of the
gas to detection for the finite number of scenarios analysed.
which can be used to inform device location. However, this technique is flawed if the following
parameters are not taken into account:
a) artificial smoke might not simulate the density of the target gas;
b) artificial smoke might have a different temperature at the source of generation than that of the
temperature of gas at a release point; and
c) artificial smoke might have a different motive force.
NOTE Some forms of artificial smoke are very acidic and could cause damage to plant and equipment.
Defining the set points at the LTEL and STEL can be impractical due to the following reasons:
a) the technology might not be capable of reliably alarming at low concentrations;
b) spurious trips;
c) the detector can be triggered during normal operation, e.g. filling/unloading; and
d) background concentration of the target gas.
Therefore, the practicalities of setting the low and high levels at the STEL and LTEL should be
reviewed and it might be more appropriate to use immediately dangerous to life or health (IDLH)
values. To guard against spurious trips due to short-lived peak concentrations, a time delay could
be incorporated into the alarm (e.g. if the set point has to be maintained for X seconds, the time
would be dependent on the particular operation) or voting could be employed, e.g. 2ooN detectors
required to alarm.
The set points for toxic gas detectors should also be reviewed against the criteria used to justify
the number of detectors for a particular area or operation (see 7.6.2), e.g. areas where egress is
difficult and/or takes an especially long time might require lower set points than those where egress
is unimpeded.
The set points should be monitored over time to ensure they are appropriate to the operation. If
detectors are continuously alarming there is the potential that they will be inhibited by operators and
hence not provide the intended function.
Unlike set points for flammable detectors, toxic set points could change as more research and data
are collected on the physiological effects of different materials. Therefore, toxic set points should be
reviewed periodically to meet current guidance.
Key
Ambient levels of toxic gas
Mitigated levels of toxic gas
Unmitigated levels of toxic gas
NOTE The dash/dot line simulates a background level of toxic gas. The solid line simulates the initial loss of
containment. Once the alert stage has activated, the gas detection system alerts occupants and instigates any
process or procedural action to remove the toxic gas. The dashed line simulates unmitigated loss of containment
that allows the gas to increase. The time allowed for mitigation represents the time trained operators can
remain. Time allowed to make occupants safe is the time required from the first activation of the gas detection
system and making the occupants safe.
Table 1 provides guidance on determining how much time is required to make occupants safe, e.g. a
congested area might take more time to evacuate. The time allowed to evacuate can be increased by
lowering the low threshold of the action/alert levels.
The type of occupant and level of knowledge impact the level of risk. Typically,
industrial applications have levels of control of occupants and training.
Active occupants Occupants who are aware of the risk and are trained how to
respond in the event of loss of containment.
Passive occupants Occupants who are not aware of the risk or trained on how
Occupancy
to respond in the event of loss of containment.
Number of occupants The number of occupants (passive or active) determines the
amount of time required to evacuate to a place of relative
safety.
Or:
• the PPM or percentages that cause harm (or toxicity) to the occupants;
• whether the gas can be seen or smelled (colourless and odourless gas
does not naturally notify the occupants of the hazard).
Nature/toxicity of
the gas Density – while some gasses can be heavier or lighter than air, variances in
temperature, humidity, ventilation, carrier gas, etc., could affect the density of the
gas or the gas might “settle”. Typically, the gas detectors should be placed at “normal
occupant breathing level”.
NOTE: The PPM or percentages regarding toxicity are set against average capacity and
do not account for occupants who might suffer from respiratory difficulties.
The equipment or process should also be clearly labelled in the reports and
accompanying drawings.
Table 1 (continued)
The risk assessment needs to identify whether the supply is part of the risk. This can
Supply pipe
be mitigated by welded joints and regular testing. If the supply pipework is not tested a
Integrity
strategy should be identified to manage the risk.
It is important to consider the supply of toxic gases and the volume of gas that even
a small container of gas might produce, e.g. a relatively small cloud of gas at 100% of
Inventory size
concentration can dissipate to an exponentially larger cloud with a harmful level (ppm)
of gas.
Set points The set points of the gas detectors should reflect the risk
and alert the occupants to the presence of toxic gas with a
significant margin before harm.
Response time The response time for the gas detectors should be
incorporated into the overall response time of the
occupants, e.g. detectors with a slow response time need
to be closer together to increase the time to evacuate. Gas
detector response time is measured as T90 (the time taken
to reach 90% of the applied concentration is used).
Table 1 (continued)
There are multiple harmful gasses which can harm occupants. Moreover, the risk gas could be altered
by a carrier or atmospheric gas which changes its nature and risk.
Comprehensive empirical data are not available for all toxic gases and the environments of
application are not repeatable for reasonable study. Consequently, toxic gas detection location design
is likely to be targeted to achieve specific goals for the occupants to take action and/or get to a
place of safety. Such goals can be presented using either prescriptive, volumetric-based methods or
scenario-based method targets. Table 1 provides a guide for the gas detection location designer to
determine the performance targets for the gas detection system.
Toxic gas detection can only detect loss of containment; it cannot protect an occupant who is
geographically closer to the loss of containment than the fixed gas detector. Consequently, the fixed
gas detector should have a quick response time and detection setting that give early warning.
The performance targets reflect the risk and mitigation as outlined in Table 1, e.g. a single application
of a toxic gas next to a walkway could have various separate performance targets:
a) scenario – to detect gas near the pumps and tanks operating at pressure;
b) volumetric – a stricter performance target to reflect that a trained operative is in the area during
normal working operations;
c) escape/communications route – a volumetric performance target to protect occupants passing
through or near to the risk; and
d) operational procedure – to protect occupants who might be working in an area that is not
normally occupied and therefore does not require permanent detection.
The performance targets are to be drafted and agreed prior to the design of the gas detector locations.
NOTE Annex D provides further guidance on risk and mitigation identification.
7.6.3 Prescriptive
Prescriptive toxic gas detector mapping refers to the use of qualitative evaluation and judgement-
based placement in the locating of gas detectors. Prescriptive toxic gas detection should have
supporting documentation that explains the design practice in accordance with Table 1. Examples of
prescriptive toxic methods include:
a) proven design that is reused for similar applications; in many instances this would not require a
full modelling activity;
b) ruleset-based approach, e.g. all escape routes will have a gas detector every X metre; and
c) evaluation of the factors in 7.4 and detectors placed at locations where gas is likely to
accumulate; this is most appropriate for applications that do not contain many potential leak
sources and releases are likely to behave in a predictable manner, e.g. no areas of recirculation.
Software modelling tools and metrics (e.g. percentage coverage) are not required when using the
prescriptive approach and compliance can often be checked using a checkbox-type approach against
the ruleset that has been employed.
measures to restrict occupancy of areas not normally occupied (outside the assessed volumes) can
include permit to work, removing the risk of gas, portable protection, etc.
Volumetric-based mapping is typically performed using software packages that verify the
coverage achieved.
The following advantages and disadvantages are generated based on common applications where
the method is selected. The critical factor is use of the most appropriate methodology to the specific
application, e.g. the exclusion of subjective factors such as wind direction or leak orientation, is a
strength in the volumetric-based approach, but if the application is a controlled environment where
variables are reduced (i.e. an internal volume with few sources of release), the exclusion of those
factors could be considered a disadvantage.
The advantages of volumetric-based mapping include:
a) 3D model can be applied for visualization purposes;
b) incorporates information on process, e.g. heat and mass balance data to determine constituents
of a potential cloud (e.g. pressure, molecular weight and temperature) to set elevation/location
of the graded volume;
c) no detailed knowledge of where leaks originate is required;
d) subjective features of analysis are reduced by comparison to scenario-based mapping, i.e. where
leaks originate, likelihood of pipe rupture, etc.;
e) relatively quick to design;
f) consistent designs; and
g) easily audited.
The disadvantages of volumetric-based mapping include:
1) results can be influenced by the size of volume assessed;
2) no clear way of determining where the graded volume should extend to; and
3) subjective features of analysis are increased by comparison to prescriptive, i.e. various cloud
sizes, coverage adequacy interpretation, etc.
A gas detector should not be selected during a mapping study based on response time only as there
is no consistency in current test methods to determine response times of a gas detector, i.e. different
test methods give different results.
If accessories are used in normal operation these should be included in the mapping study, e.g. effects
on speed of response or gas detector availability.
f) sampling points: for aspirated systems, the use of integral dust filters, ball floats, calibration
valves, etc., might or might not affect the performance.
7.6.7.3 Recovery
The recovery of a gas detector after a deluge/high exposure to gas is important for the overall
mapping study with respect to gas detector availability.
Certain gas detector technologies have a long recovery duration if over-exposed to gas and are
therefore unable to detect reoccurring gas leaks until a full recovery has been realized.
Gas detectors which are over-exposed might not recover and need to be replaced.
7.6.7.4 Concentration
No gas release has a uniform concentration once dispersed into the ambient environment. At
points closest to a release the concentration is much higher than monitoring points at a distance
from a release.
High gas concentrations do not typically improve response times of the gas detector but can improve
the time to alarm. Background or ambient gas concentrations might cause spurious trips if measuring
ranges are too small.
7.6.7.5 Calibration
All gas detectors should be calibrated for the target gas they are intended to detect. For a calibration
to be correct, the composition of the calibration gas should be known and validated with a gas
composition certificate – this includes the balance gas composition, e.g. the make-up of synthetic air.
Many gas detectors have known cross-sensitivities which give either a positive or negative effect,
e.g. ammonia electrochemical sensors are cross-sensitive to many amine gases, so known cross-
sensitivities should be accounted for during the mapping study.
NOTE If surrogate, less dangerous gases are used for calibration, the effects of a surrogate calibration with
respect to accuracy and response times might need to be determined during the mapping study.
8 Detailed engineering
8.1 General
Typically, before detailed engineering begins, preliminary F&G layouts are issued. These layouts are
required to be produced early in the project life cycle to enable purchase of long lead items such as
F&G systems cabinets. F&G layouts are typically produced using engineering judgement and a more
prescriptive approach. However, once the design has become fixed and stable, more detailed mapping
work can be undertaken. Irrespective of the approach selected, the guidance provided in 8.2 to 8.4 is
very important during detailed engineering.
If changes are required as a result of significant model changes it might not be practicable or
possible to repeat mapping. However, by using gas concentration “heat maps” (commonly produced
from dispersion mapping studies), an approximate assessment and change can be made using
engineering judgement.
Figure 12 shows an example of the level of ventilation within an enclosed facility. The warmer
colours show high air velocities and the colder colours show low air velocity. A heat map (as shown
in Figure 12) can be used to determine whether a change has occurred in a critical location and to
provide some understanding of the general physical processes that are dominant or occurring in a
given location. In this way these maps can be an important tool in assessing and reacting to changes.
Figure 12 — Example of ventilation analysis
k) layout plans for the recording of the location, elevation, orientation and field of view of all
F&G detectors;
l) procedures for corrective actions, system modifications or changes to the location, elevation,
orientation and field of view of any single or multiple F&G detectors;
m) test gases to be used, supported by valid gas composition certificates;
n) test torch or equivalent (manual walk/view exercise) to be used for checking the field of view for
each individual flame detector; and
o) any exclusions.
9.2 Execution
The installation should be conducted in accordance with the installation plan which gives details to
support the location, elevation, orientation and field of view for all F&G detectors.
Commissioning should be conducted in accordance with the commissioning plan.
All installation and commissioning activities are to be documented and be fully transparent and
relevant for future periodic inspection reviews.
Before installation and commissioning can be performed, all documentation is to be checked for:
a) completeness; and
b) correct revision, including cross references.
All documents are to be approved by a competent person.
If a device/system failure or location error is discovered during commissioning, the reason for the
failure or the location error needs to be identified and documented. A decision needs to be taken as
to whether to:
1) repair the failure or relocate a detector, including the adjustment of elevation, orientation or field
of view and continue with the commissioning exercise; or
2) ignore, but document the failure or location error and complete the commissioning exercise; or
3) if the failure affects the total system or multiple detectors, abort the complete commissioning
exercise, allowing the failure to be repaired or the location of detectors to be corrected, with a
new commissioning date being arranged; or
4) partially complete the commissioning exercise and plan an additional final commissioning
activity after corrective actions have been taken.
If during the commissioning exercise any modifications or changes are made to the system or
the location of any gas or flame detector, these changes should be subject to a safety analysis
to determine:
i) the results of a new mapping exercise (if required);
ii) the extent of impact on each safety function; and
iii) the extent of re-test which should be defined and implemented.
All modifications are to be documented and approved by a competent person.
10 System validation
COMMENTARY ON CLAUSE 10
For the purposes of this British Standard, validation is defined as a process which confirms that the
design intent of the fire and gas system has been met. This may include the mapping premises, design
assumptions and checks that the implementation achieves desired coverage following commissioning.
This is different from “verification”, which in the context of F&G is a process to confirm that the design
specification has been implemented correctly, and for the purposes of this document is met through
commissioning and installation (see Clause 9).
10.1 Planning
Prior to commissioning, a system validation plan should be prepared and include, as a minimum:
a) validation methods so that the installed F&G detection system delivers the coverage factor as
specified in the mapping study;
b) validation methods so that the installed F&G detection system operates correctly under:
1) normal operation;
2) abnormal operation (e.g. detector beam blocked by snow on transmitter/receiver optical
window, obstructions being placed in the line of sight);
3) special state condition;
4) fault condition; and
5) normal changes in use, occupancy and configuration of the monitored/process area;
c) a method to include any system modification which might have been implemented during the
factory acceptance test or system installation or commissioning;
d) validation of the competencies of persons in attendance;
e) procedures for the recording of test data/results and the hardware/software versions of the
equipment under test; and
f) layout plans for the recording of the location, elevation, orientation and field of view of all
F&G detectors.
If during the system validation test any modifications or changes to the system are made, these
changes should be subject to a safety analysis to determine:
i) the results of a new mapping exercise;
ii) the extent of the impact on each safety function; and
iii) the extent of re-test which should be defined and implemented.
Until all of the requirements detailed in the system validation test plan are validated, the F&G
detection system is not operational.
11.2 Planning
The need for operation planning should be specified during the design phase of the F&G detection
system and at regular intervals during the operational phase to ensure continued compliance.
Changes to any operational requirements or processes should take into account the guidance given
in Clause 10.
Planning should ensure, as a minimum, that:
a) a procedure is in place so that only authorized personnel have direct access to F&G detector
field devices;
b) a system design criterion for normal operation is readily available;
c) operational personnel have full knowledge of F&G detector objectives, operating principles and
limitations and, if applicable, any relevant operational procedures per device;
d) alarm shelving procedures include criteria and detection criticality factors of F&G detectors;
e) how the number of demands placed on the F&G are recorded;
f) if known, the number of missed detection scenarios are recorded;
g) any misuse or abnormal operation of a flame or gas detector are recorded;
h) applicable environmental data associated with each detector location are considered;
i) the frequency of scheduled system maintenance activities is recorded;
j) actions to be taken in an unplanned event are in place, e.g. if the F&G system fails during either
operation, maintenance or modification, there is a back-up plan to deploy transportable gas
detection zone monitors or fire watchers to observe the plant area for hazards; and
k) regular reviews are carried out to determine whether any process changes have affected the F&G
detector coverage factor.
11.4 Maintenance
11.4.1 Planning
The need for maintenance planning should be specified during the design phase of the F&G detection
system and repeated during the operational phase, as necessary.
Changes to any maintenance activity should take into account the guidance given in Clause 10.
The impact of peripheral and other maintenance activities on F&G detector coverage should be taken
into account.
Planning should ensure, as a minimum, that:
a) only authorized and competent personnel have direct access to F&G detector field devices;
b) detailed maintenance activities and procedures are readily available and revision‑controlled;
c) the frequency of scheduled system maintenance activities is recorded;
d) the frequency of scheduled system validation activities and reviews of coverage applicability
is recorded;
e) any abnormal maintenance schedules are authorized by competent personnel who have written
authority to approve such activities;
f) the maximum number of F&G detectors which are in override (inhibit) during any maintenance
activities are known;
g) additional operational measures to be taken during maintenance activities are known and used,
e.g. temporary deployment of zone gas detectors;
h) detailed maintenance records are kept, including device location and orientation, fitted
accessories, device viewing angles, faults found, inconsistencies, corrective or repair actions
taken, spare parts used, consumables used and any changes of system performance which might,
in the future, affect the detector coverage factor;
i) any identified environmental factors are identified which might affect the performance of a flame
or gas detector; and
j) detailed proof test results are available, including speed of response and recovery times.
The F&G detection system is to be maintained as detailed in the overall system maintenance plan.
Only transmitters/detectors, spare parts and consumables listed in the safety manual or individual
equipment maintenance manuals are to be used.
The F&G detection system is to be proof-tested as detailed in the system safety manual.
All activities are to be clearly documented.
11.5.2 Execution
A modification activity should not commence without proper authorization.
All modifications should be documented, verified and validated, and follow the modification plan,
modification documents and modification instructions. The documentation should be revised and
signed off by the person/department responsible for maintaining the document.
Any deviation from the modification plan should be authorized and, if necessary, a new impact
analysis performed. If the impact analysis reveals unacceptable risks, the emergency plan should
be followed.
Upon completion of the modification the entire part system or complete system should be validated
to prove the safety function. An impact assessment is required to determine the extent of this
validation. Modification is not complete until all training activities are complete.
12 Competence
Competence is:
a) the ability to undertake responsibilities and to perform activities to a recognized standard on a
regular basis; and
b) a combination of practical and thinking skills, relevant experience and knowledge.
All persons, departments or organizations involved in F&G mapping should be able to
demonstrate competence.
As a minimum, for the roles and responsibilities of individuals, the following is to be addressed when
assessing competence:
1) knowledge of and education about the appropriate local, national and international standards
applicable to F&G detection systems, including those standards set out in the bibliography;
2) appropriate knowledge of the legal and safety regulatory requirements pertinent to
F&G detection;
3) engineering knowledge, education and relevant experience appropriate to:
i) the specific hazards and required risk analysis;
ii) the detection technologies of F&G detectors;
iii) the complexity and novelty of a F&G detection system design, which could be complex
due to size and logic or relatively novel due to its design or application, requiring a higher
degree of rigour with respect to competence; and
iv) the application or use of the F&G detection system;
4) understanding of the potential consequences of an event if a gas leak or open flame is not be
detected; and
5) previous experience and its relevance to the specific duties performed to support and complete a
F&G detection mapping study.
Annex A (informative)
Oxygen enrichment and deficiency
A.1 General
Typically, there are four main hazards or conditions when the concentration of oxygen needs to
be measured:
a) oxygen enrichment – hazard is increased risk of ignition or fire;
b) oxygen deficiency – hazard is asphyxiation;
c) condition monitoring – minimum oxygen content for explosion protection; and
d) condition monitoring – guarding against oxidation.
The most frequent measurement of oxygen concentration is associated with confined space entry and
working. For this application, the positioning of the gas detector, e.g. personal monitor, is within the
breathing zone (carried on the person) or directly adjacent to the working space within the confined
space environment. This application only requires a prescriptive safety procedure and is supported
by the Safety, Health and Welfare at Work (Confined Spaces) Regulations 2001 [11]. Where forced
ventilation is used for confined space working, any fixed oxygen gas detector is to be located in both
the air intake and the air outlet as a minimum. A prescriptive safety procedure controls the location
of an oxygen fixed gas detector.
Fixed gas detectors are not typically used to monitor confined spaces as the primary method of
detection is by personal monitors. However, where fixed gas detectors are used to support personal
monitors they are to be located to provide optimum coverage, e.g. in and around the work location.
Oxygen monitoring in the workplace typically occurs indoors where a prescriptive or
volumetric‑based method for detector placement is sufficient. Alternatively, basic air current testing
using buoyant smoke tests can be useful.
NOTE All % v/v figures are approximate and based upon standard temperature and pressure. Altitude greatly
affects the partial pressure measurement of oxygen.
Annex B (informative)
Flame detection – Example of volumetric-based mapping
COMMENTARY ON ANNEX B
This annex provides a worked example showing one possible representation of flame detection mapping.
B.1 General
It is assumed the area has been processed through a risk assessment (see Clause 4 and 7.3.2). Vessels
V-001 and V-002 present a medium risk to the area (containing pressurized flammable liquid). Vessel
V-003 presents a low risk as it is a storage vessel for flammable liquid at atmospheric pressure.
Table B.1 shows the performance targets applied to the area.
Table B.1 — Flame detection performance targets
Graded volume
Equipment Fire size (RHO) Fire size (RHO) control
Grade extension from
tag alarm (1ooN) action (2ooN)
equipment
m kW kW
Medium risk
V-001 2 50 100
(MR)
Medium risk
V-002 2 50 100
(MR)
Low risk
V-003 2 250 500
(LR)
Figure B.1 represents the volume in digital form, where performance targets and detectors
can be placed.
Figure B.2 and Figure B.3 represent the performance targets generated from the risk assessment.
Figure B.4 represents the detector locations and Figure B.5 and Figure B.6 represent the assessment
of coverage. A generic flame detector cone has been applied in the example. In reality, the specific
flame detector being installed is to be modelled.
Figure B.1 — Volume to be mapped
Key
1 Low risk (LR) – 2 m extension
2 Medium risk (MR) – 2 m extension
Key
Low risk
Medium risk
Key
Medium risk area of coverage
Key
Low risk
Medium risk
Key
Alarm
Control action
No coverage
Minimal
NOTE The flame detection footprint cone is representative of the detection distance to a 10 kW RHO flame. This
is for illustrative purposes only and does not reflect the capability of the device. Flame detection capability is
assessed as per the inverse square law (see Clause 7). “Minimal” coverage represents a location where the target
fire size is not within range, but if it grows beyond the specified target, it will be detected by a single device as a
clear line of sight exists to that point.
From this point, the engineer applies judgement to determine coverage adequacy. If significant
gaps exist where fires could burn undetected, or redundancy is required, additional detection can
be considered. An additional detector is added for clarity in Figure B.7, with the resulting coverage
impact represented in Figure B.8 and Figure B.9.
Figure B.7 — Proposed additional flame detector
Key
B:
C:
Key
Alarm
Control action
No coverage
Minimal
Key
1ooN = 28%
2ooN = 0.0%
>2ooN = 0.0%
Key
1ooN = 28%
2ooN = 0.0%
>2ooN = 0.0%
Figure B.12, Figure B.13 and Figure B.14 show the coverage achieved using two flame detectors.
Key
1ooN = 43%
2ooN = 5%
>2ooN = 0.0%
Key
1ooN = 43%
2ooN = 5%
>2ooN = 0.0%
Figure B.14 and Figure B.15 show the coverage achieved using three flame detectors.
Key
1ooN = 58%
2ooN = 14%
>2ooN = 2%
Key
1ooN = 58%
2ooN = 14%
>2ooN = 2%
Annex C (informative)
Flammable gas detection – Volumetric-based mapping
COMMENTARY ON ANNEX C
This annex provides an example of volumetric-based mapping.
C.1 General
It is assumed that a risk assessment has been conducted and the requirement for gas detectors has
been identified (see 7.5). The plant is outside and has low congestion. There is a concern that an
accumulation of flammable gas could ignite, causing explosion overpressures exceeding 150 mbarg
and leading to personnel fatalities and damage to the facility.
Table C.1 shows the estimated blockage ratio within the area.
Table C.1 — Estimated blockage ratio
As the volume is relatively open with little congestion and confinement, the volume is classed as open.
With the concern being the ignition of a volume of gas causing an explosion, judgement has been used
to set the target gas cloud size as 10 m in diameter (twice the 5 m cloud size historically used).
The facility has a 2ooN voting configuration for both low- and high-level alarms. A dilution factor of
three is applied to account for the difference in cloud size between low- and high-level alarms. The
high alarm target gas cloud size is 10 m and the low alarm target cloud size is 30 m.
The target gas clouds sizes, detection technology and set points are summarized in Table C.2.
Table C.2 — Flammable gas detection performance targets
Target gas
Congestion High alarm set High alarm Low alarm set Low alarm
cloud of
category point target cloud point target cloud
concern
10 m diameter Point GD – Point GD –
10 m 30 m
Open cloud of 100% 20%LEL 10%LEL
LEL OPGD – 3.0LELm 10 m OPGD – 1LELm 30 m
Figure C.2 represents the volume over which the volumetric-based mapping is performed, and
adequacy is assessed.
Figure C.2 — Grademap volume
Key
A combination of infrared open-path and infrared point gas detection technology is applied to the
area, as shown in Figure C.4.
Figure C.4 — Existing gas detectors
Key
Alarm: 57%
No coverage: 10%
Key
Alarm: 57%
No coverage: 10%
As stated in 7.5.6, percentage coverage in isolation is not to be used to determine coverage adequacy.
If significant gaps exist where the cloud volume of concern remains undetected, or redundancy is
required, additional detection needs to be determined. An additional detector is added for clarity in
Figure C.7. The updated coverage assessment is shown in Figure C.8 and Figure C.9.
Figure C.7 — Updated detection layout
Key
Alarm: 33%
Key
Alarm
Control action
Annex D (informative)
Risk and mitigation identification
D.1 General
The performance targets (PT) are to reflect the specific risks and mitigations for the site. The audit
of the gas detection system and device locations is based on the risk mitigation and subsequent PT
(see Table D.1 for an example of facility information).
Table D.1 — Example of facility information
Toxic gas Chlorine is present and being loaded into pressurized bottles. When liquid
chlorine is released, it quickly turns into a gas that stays close to the ground and
spreads rapidly. Chlorine gas can be recognized by its pungent, irritating odour.
The site has large volumes of chlorine available in a pressurized and industrial
environment. The strong smell is an inadequate warning to occupants that they
are exposed. Chlorine gas appears to be yellow-green in colour.
Chlorine can also react explosively or form explosive compounds with other
chemicals, such as turpentine and ammonia.
The end-user is required to specify detection levels for the gas detection system.
Guidelines to take into account include:
1–3 ppm Mild mucus membrane irritation that can usually be
tolerated for approximately an hour.
5–15 ppm Moderate mucus membrane irritation.
30 ppm and beyond Immediate substernal chest pain, shortness of breath and
coughing.
40–60 ppm Toxic pneumonitis and/or acute pulmonary oedema can
develop.
400 ppm and Generally fatal over 30 min.
beyond
1 000 ppm and Fatality ensues within only a few minutes.
above
NOTE 2 These numbers are indicative for a “normal” occupant who is not
suffering from any pneumatic disorders (asthma).
Gas detection can be set for two levels (concentrated gas and diluted gas) – early
warning needs to be determined at the lower level ppm. The site might already
have predetermined detection levels.
Table D.1 (continued)
Occupants All occupants in the area are trained to evacuate in the event of the alarms
activating. Occupants are trained to use breathing apparatus in the event of the
loss of containment for response and rescue.
Each area has a sounder beacon to alert that an individual device has been
activated.
Outside contractors need to be briefed and inducted regarding the risk when
working in the area.
Contractors’ on site who are unfamiliar with the site require more time to
evacuate.
Table D.1 (continued)
Each area has a sounder beacon to alert that an individual device has been
activated.
The installed gas detectors are gas alarm systems model XXX. No information
was provided by the site or the manufacturer regarding the type of gas detector
installed. The part number listed is XXXX82-052; however a data sheet was not
available publicly.
The gas detectors are reported to have only a single level of alarm.
Supply pipe integrity The system is relatively new – this gas detection risk assessment does not
consider the pipework feeding the process. However, the site needs to consider
undertaking and recording a regular integrity test.
Given:
Given:
Given:
Annex E (informative)
Graphic symbols for fire and gas detection
location drawings
COMMENTARY ON ANNEX E
BS 1635 has been produced with the agreement of the Fire Standards Policy Committee. During
preparation ISO 6790 (withdrawn) was considered and its symbols have been used wherever possible,
with consideration of the content of BS 1635.
If an organization has established symbols, this annex does not preclude continued application.
The initiating equipment (detectors) has been organized into elements and symbols. Any detector is
symbolized as a square.
4.201 detector, any type
Beam – an arrow
Gas – a triangle
Detail required in the latest F&G detection location designs is not included. The amount of
information (detail) provided by the graphic symbol provides:
a) location;
b) tag reference;
c) device type;
n = the number of
detection pipes.
Point heat detector No change –
temperature or
rate of rise to be
specified in separate
schedule.
Linear heat detection The K symbol
indicates control
unit/interface. The
line indicates the
run of the detection
line.
Details of heat
detection to be
specified in separate
schedule.
Table E.1 (continued)
• type of detection;
• pan in degrees
(horizontal
orientation in
relation to building
north); and tilt in
degrees (vertical
orientation to the
horizon).
Flammable/toxic point * = chemical
gas detector notation/formula of
gas being detected
or [i.e. methane
Sample for chlorine point gas detector detector would be
“CH4” or chlorine
would be “Cl”)].
Table E.1 (continued)
Or
n = the number of
detection pipes.
Bibliography
Standards publications
For dated references, only the edition cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies.
BS 1635, Recommendations for graphic symbols and abbreviations for fire protection drawings
BS 5839‑1, Fire detection and fire alarm systems for buildings – Part 1: Code of practice for design,
installation, commissioning and maintenance of systems in non-domestic premises
BS EN 54‑10, Fire detection and fire alarm systems – Part 10: Flame detectors – Point detectors
BS EN 60079‑29‑2, Explosive atmospheres – Gas detectors – Selection, installation, use and
maintenance of detectors for flammable gases and oxygen
BS EN 50104, Electrical apparatus for the detection and measurement of oxygen – Performance
requirements and test methods
BS EN 45544‑1, Workplace atmospheres – Electrical apparatus used for the direct detection and direct
concentration measurement of toxic gases and vapours – General requirements and test methods
BS EN 45544‑2, Workplace atmospheres – Electrical apparatus used for the direct detection and direct
concentration measurement of toxic gases and vapours – Performance requirements for apparatus used
for exposure measurement
BS EN 45544‑3, Workplace atmospheres – Electrical apparatus used for the direct detection and direct
concentration measurement of toxic gases and vapours – Performance requirements for apparatus used
for general gas detection
BS EN 45544‑4, Workplace atmospheres – Electrical apparatus used for the direct detection and
direct concentration measurement of toxic gases and vapours – Guide for selection, installation, use
and maintenance
Other publications
[1] GREAT BRITAIN. The Health and Safety at Work Act 1974. London: The Stationery Office.
[2] GREAT BRITAIN. The Dangerous Substances and Explosive Atmospheres Regulations 2002.
London. The Stationery Office.
[3] GREAT BRITAIN. The Control of Substances Hazardous to Health Regulations 2002. London:
The Stationery Office.
[4] FM APPROVALS. FM 3260, Approval criteria for Radiant Energy-Sensing Fire Detectors for
Automatic Fire Alarm Signaling. Massachusetts, U.S.A: FM Approvals, 2018.
[5] GREAT BRITAIN. Control of Major Accident Hazards Regulations 1999 (COMAH). London:
The Stationery Office.
[6] HEALTH AND SAFETY EXECUTIVE. The selection and use of flammable gas detectors. London:
The Stationery Office, 2004.
[7] HEALTH AND SAFETY EXECUTIVE. Research report RR1123. Fixed flammable gas detector
systems on offshore installations: optimisation and assessment of effectiveness. London:
The Stationery Office, 2017.
[8] HEALTH AND SAFETY EXECUTIVE. Report OTO 93 002. Offshore Detector Siting Criterion
– Investigation of Detector Spacing by Lloyds Register, Offshore Technology Report. London:
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ATKINSON. G., COWPE, E., HALLIDAY, J., PAINTER, D. A Review of Very Large Vapour Cloud Explosions.
HSL Report MH15/80.
GREENHAM, L. The CoGDEM guide to Gas Detection. ILM Publications. 2012.
ISBN: 978‑1-906799-16-8.
HEALTH AND SAFETY EXECUTIVE. EH40/2005. Guidance on ALARP Decisions in COMAH.
(https://www.hse.gov.uk/foi/internalops/hid_circs/permissioning/spc_perm_37/)
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