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KARIMUN YARD CONSTRUCTIONPROJECT

SITE ACCEPTANCE TEST

(AIR VANTILATION SYSTEM FOR POWERPLANT)

Date: 21-12-2010 Doc no. 863013-VPS-PQM -C-DS-0002 Rev. 0 Page 1 of 24

KARIMUN YARD CONSTRUCTION PROJECT


Contract No.: 537856

863013-VPS-PQM-E-DS-0002

21-12-2010 A Issue for REVIEW HFZ MPS JBS

Date Revision Revision description Prepared Checked Approved

This document is the property ofSaipem.; all rights reserved. Violators will be pursued under civil and criminal law


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SUMMARY OF REVISION

Revision Revision description Prepared Checked Approved

21-12-2010 A Issue for REVIEW HFZ MPS JBS


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CONTENTS

Description Page No

SUMMARY OF REVISION ...2

CONTENTS .....3

INTRODUCTION.....................................................................................................................4

SYSTEM DESCRIPTION........................................................................................................5

PURPOSE ....5

EQUIPMENT REQUIRED ..5

COMMISSIONING METHODE ..6

1. PARTICULARS ..6

1.1 Ventilation Fan 3608 VPS 01 ....6

1.2 Ventilation Fan 3616 VPS 02 ...7

1.3 Electrical Control Panel VPS 01 ..7

1.4 Electrical Control Panel VPS 02 ..8

2. VENTILATION FAN TEST ......8

3. STARTING TEST......8

4. PREPARATION CHECK 10

4.1System Checklist .......10

4.2Mechanical Installation ..10

4.3Electrical Installation ..10

4.4 Inspection by Vendor Service Engineer or Technical Representative ........11


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5. PRE-COMMISSIONING PROCEDURE CHECKLIST 12

5.1Air Duct ....12

5.2 Fans .12

5.3Electrical Control Panel ....13

6. COMMISSIONING PROCEDURE ...14

6.1Operational Test ....14

6.2Air Duct, Enclosure, and Fans performance Test ....14

7. APPENDICE ....15

7.1Functional Checklist VFD Control Panel Fan 3608 VPS 01 ...16

7.2 Functional Checklist VFD Control Panel Fan 3608 VPS 01 ...17

7.3Commissioning Checklist and Record Fan 3608 - VPS 01 18

7.3.1 Commissioning Record Fan 3608 VPS 01 .....18

7.3.2 Running Record Fans 3608 VPS 01 ...........19

7.4Commissioning Checklist and Record Fan 3616 VPS 02 ...20

7.4.1 Commissioning Record Fan 3608 VPS 01 .....20

7.4.2 Running Record Fans 3608 VPS 01 ...21

ACCEPTANCE ..22


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SYSTEM DESCRIPTION

The ventilation requirements of a space will be largest air flow of the three quantities determined by:

1. The rate of air change.

2. The required fresh air flow per equipment.

3. The limiting temperature rise.

The requirement of rate of outside air change for all specs, and allowable temperature rise are given in table in

table 7.0 at appendices rise as general guideline.

This procedure covers Engine/ Generator area.

PURPOSE

1. To ensure proper installation of fans, short duct, flexible duct, discharge attenuator, silencer box.

2. To demonstrate the operational of equipments.

3. To ensure functionality of equipment control and device.

EQUIPMENT REQUIRED

1. Ammeter.

2. Voltmeter.

3. Anemometer.

4. Megger Tester

5. Thermometer

6. Sound meter


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COMMISSIONIN G METHODE

1. Particulars

1.1 Ventilation Fan 3608 VPS 01Fan Unit : 1 Set

Fan

Manufacture : Viking Engineering / Meta Vent

No. of Unit : 1 Set

Model : Meta Vent 1400/11-11/D-36

Air Volume : 120,000 Cmh

Static Pressure : 350 Pa

Fan Electric Motor

Power Output : 37 kw

Electric Source : 400V/3Ph/50Hz

Speed : 960 rpm

Space heater : 230V/1Ph/50Hz/60w

C/W PTC Thermistor

1.2 Ventilation Fan 3616 VPS 02

Fan Unit : 1 Set

Fan

Manufacture : Viking Engineering / Meta Vent

No. of Unit : 1 Set

Fan Model : Meta Vent 1900/11-11/DX-29


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Air Volume : 200,000 Cmh

Static Pressure : 350 Pa

Fan Electric Motor

Power Output : 55 kw

Electric Source : 400V/3Ph/50Hz

Speed : 720 rpm

Space heater : 230V/1Ph/50Hz/80w

C/W PTC Thermistor

1.3 Electrical control panel fan 3608 VPS 01

Electrical Control panel Unit : 1 Set

Manufacture : Viking Engineering / Viking instrument

No. of Unit : 1 Set

Voltage : 400 Volt

Current Amp : 66.5 Amp

C/w Variable frequency drive Altivar 61 to control speed motor fan include

temperature sensor, will be install on inside enclosure and outlet air on room.

1.4 Electrical control panel fan 3616 VPS 02

Electrical Control panel Unit : 1 Set

Manufacture : Viking Engineering / Viking instrument

No. of Unit : 1 Set

Voltage : 400 Volt

Current Amp : 99.4 Amp

C/w Variable frequency drive Altivar 61 to control speed motor fan include

temperature sensor, will be install on inside enclosure and outlet air on room.


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2. VENTILATION FAN TESTING

After each mechanical ventilation system having been finished fan installation, power feeder termination

and louver, silencer box, wire mash, short duct, flexible duct and discharge attenuator, pre-commissioning

shall be performed clamp skid fan, fan rotation etc.

The following ventilation items shall be observed under system operation:

a) Working condition (vibration, noisy etc)

b) Fan motor voltage

c) Fan motor running current

d) Running air flow

e) Noisy running fan

f) Temperature

Before the ventilation test shall be proceed, to confirm the integrity of duct installation, inlet louver and

discharge attenuator ventilating unit installation.

During the above start up, air inlet louver, discharge attenuator to be kept fully open. After the supply fan

start up, the supply air quantity to supply engine /generator. The air flow to be taken record air flow on

outlet enclosure fan, the air flow obtained shall not be less than 90% of the design data.

3. STARTING TEST

Preparation of test: Before Start the ventilation fan check power voltage, 400AC must be

powered up to the panel.

Ventilation fan control Panel is Controlled by Schneider Electric Altivar 61, VFD Altivar 61 comes

along with a display unit.

The display unit with start/ stop buttons, but were disabled due to requirement of the Main

Generator and Emergency Generator override control.

Nevertheless, should there is requirement to stop of the fan in case Emergency. The Emergency

push button can be use.

No Out side

temperature

As per Required: 10C less

than Outside Temperature

Remarks


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1 35C 25C

2 34C 24C

3 33C 23C

4 32C 22C

5 31C 21C

6 30C 20C Fan will run at minimum

7 29C 20C Speed when the internal

8 28C 20C Temperature reaches 20C

9 27C 20C

The fan speed will remain at 50Hz at all condition till the above required temperature is

achieved. Once the internal temperature is achieved, the fan will run at 30Hz.


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ITEM DESCRIPTION CHECK

4 .0 PREPARATION CHECK

4.1 System checklist

Refer to enclosure Air duct, discharge attenuator, silencer, fans and drawing

before any checking.

4.2 Mechanical Installation

4.2.1 Mechanical completion reports (Enclosure)

4.2.2 Mechanical completion reports (Discharge Attenuator)

4.2.3 Mechanical Completion reports (Insulation Enclosure)

4.2.4 Mechanical Completion reports (Clamp Skid Fans)

4.3 Electrical Installation

4.3.1 Electrical Completion reports (Cables Clamping)

4.3.2 Electrical Completion reports (Cable Marking)

4.3.3 Electrical Completion Reports (Cable Ladder)

4.3.4 Electrical Completion reports (Cable Arrangement)

4.4 Inspection by Vendor Service Engineer or Technical Representative

The following checks and inspections shall be carried out by

vendor or service engineer

4.4.1 All the mechanical components of the system are installed to vendors

specification

4.4.2 All the electrical components of the system are installed to vendor

specification

4.3.3 Vendors service engineer or technical representative to verified that the system

is ready and safe to be start-up and commissioning


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ITEM DESCRIPTION CHECK

5.0

PRE-COMMISSIONING PROCEDURE CHEKLIST

5. 1 Air Duct

5.1.1 Check enclosure leg mounting bolt should be fix and tight

5.1.2 Check air inlet louver connection mounting bolt should be fix

and tight

5.1.3 Check perforated plate cover insulation enclosure should be fix

5.1.4 Check silencer box connection should be fix and tight

5.1.5 Check discharge attenuator connection should be fix and tight

5 .2 Fans

5.2.1 Check and confirm installation of fans.

5.2.2 Verify nameplate for fans.

5.2.3 Check fan housing and duct grounded should be properly, fix

and tight.

5.2.4 The fans and the other duct work accessories have been

correctly/properly


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ITEM DESCRIPTION

6.0 COMMISSIONING PROCEDURE

6 .1 Operational Test

By referring to the table 7.3 - 7.4 carry out the following procedures

and record data.

6 .2 Air Duct, Enclosure and Fans Performance Test

6.2.1 Run the fans for a sufficient period of time

6.2.2 Energize and check operation fans (see table 7.3.1, 7.3.2 and 7.4.1,

7.4.2)

6.2.3 Check for abnormal vibration and noise of fans

6.2.4 The reading to be recorded after 1 hours of continuous operating the

system.


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7.0 APPENDICES


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7.1 Functional Check list VFD Control Panel VPS 01 .

N

o.

Description Che

ck

Remarks

1 Power Supply:

4 Ph, 400VAC, 220VAC, 50 Hz

2 Each point function test with signal injection

4-20mA Signal is injected to simulate the

temperature Read out.


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3 Key button 0peration:

Start, Stop, E-Stop, and all Other button

tested.

4 Alarm test to all point:

Motor Overload, Motor Open Circuit, PTC

Thermistor.

5 Output Test for all points including trip and

alarm lights:

Light and Indication.

6 Input test for signal:

Motor speed test for High and Low Speed with

simulated input current.

7 Completed system function test:

Yes / No

8 Total number of point tested

The output reflects as required 50Hz and

30Hz.

9 Test sticker applied:

OK.

7.2 Functional Check List VFD Control Panel VPS 02.

N

o.

Description Che

ck

Remarks

1 Power Supply:

4 Ph, 400VAC, 220VAC, 50 Hz

2 Each point function test with signal injection:

4-20mA Signal is injected to simulate the


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temperature Read out.

3 Key button 0peration:

Start, Stop, E-Stop, and all Other button

tested.

4 Alarm test to all point:

Motor Overload, Motor Open Circuit, PTC

Thermistor.

5 Output Test for all points including trip and

alarm lights:

Light and Indication.

6 Input test for signal:

Motor speed test for High and Low Speed with

simulated input current.

7 Completed system function test:

Yes / No

8 Total number of point tested

The output reflects as required 50Hz and

30Hz.

9 Test sticker applied:

OK.


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7.3. COMMISSIONING CHECKLIST AND RECORD FAN 3608 VPS 01

NO DESCRIPTION Check/Supply REMARKS

1Power supply (24VDC / 110VAC / 220 VAC/Other - state

400VAC

2 Key Button & OperationStart

Stop

Main Gen Stop.

EmergencyGen. StopOverload

Motor O/C

ThermistorOpen/High(3K)

ThermistorShort/toolow(50)

3 Each Point function test with signal injectionExternal SensorInternal SensorMotor Speed

33 33 33

24 23 22

External SensorInternal SensorMotor Speed

30 30 30

21 20 19


29 29 29

20 19 18


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INSPECTION RESULT

PASS WITHIN LIMITS PASS BY CONCESSION RELEASED FOR

USE/DELIVERYYES NO YES NO YES NO

7.3.1 Commissioning Record Fan 3608 -

VPS 01

Item Description

Insulat

ion

Resistan

t

Remark

s

Design

Data Measured M

Fan Motor Power (Kw) 37.0

Fan Motor Power

supply (V/ph/Hz)400/3/50

Fan Motor Current (A) 66.8

7.3.2 Running Record Fan 3608 - VPS 01

Frequency Voltage Current Velocity VolumeNoise(dbB)

( Hz ) ( Volt )

( Amp

) ( m/s )

( Cmh

) 0 - 5 m 0-10 m 0 - 15 m 0 - 20 m


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TESTED BY APPROVED BY (if applicable)

Name & Signature Date & StampName & Signature Date

& Stamp

7.4 COMMISSIONING CHECKLIST AND RECORD FAN 3616 VPS 02

NO DESCRIPTION Check/Supply REMARKS

1Power supply (24VDC / 110VAC / 220 VAC/Other - state

400VAC

2 Key Button & OperationStart

Stop

Main Gen Stop.

EmergencyGen. Stop

Overload

Motor O/C

ThermistorOpen/High(3K)

ThermistorShort/toolow(50)

3 Each Point function test with signal injectionExternal Sensor

Internal SensorMotor Speed

33 33 33

24 23 22


30 30 30

21 20 19


29 29 29

20 19 18

7.4.1 Commissioning Record Fan 3616 -

VPS 02

Item Description Insulat

ion

Resistan

t

Remark

s

Design

Data

Measured M

Fan Motor Power (Kw) 55.0

Fan Motor Power

supply (V/ph/Hz)400/3/50

Fan Motor Current (A) 99.4


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INSPECTION RESULT

PASS WITHIN LIMITS PASS BY CONCESSION RELEASED FORUSE/DELIVERY

YES NO YES NO YES NO

7.4.2 Running Record Fan 3616 - VPS 02

Freque

ncy

Volta

ge

Curre

nt

Veloci

ty

Volu

meNoise

(dbB)

( Hz ) ( Volt )

( Amp

) ( m/s )

( Cmh

) 0 - 5 m 0-10 m 0 - 15 m 0 - 20 m

TESTED BY APPROVED BY (if applicable)

Name & Signature Date & StampName & Signature Date

& Stamp


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ACCEPTANCE

The Equipments/ system covered under this commissioning procedure has been

tested and found to be working satisfactory manner in accordance with the test and

inspection herein.

Representative Name Signature Date

Owner : ______________ ___________________ _________________

Viking : ______________ ___________________ _________________

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