KARIMUN YARD CONSTRUCTION PROJECT

SITE ACCEPTANCE TEST

(AIR VANTILATION SYSTEM FOR POWER PLANT) PT.VIKING ENGINEERING

Date: 21-12-2010 Doc no. 863013-VPS-PQM -C-DS-0002 Rev. 0 Page 1 of 16

KARIMUN YARD CONSTRUCTION PROJECT

SITE ACCEPTANCE TEST

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 of Saipem.; all rights reserved. Violators will be pursued under civil and criminal law

SUMMARY OF REVISION
 KARIMUN YARD CONSTRUCTION PROJECT

SITE ACCEPTANCE TEST

(AIR VANTILATION SYSTEM FOR POWER PLANT) PT.VIKING ENGINEERING

Date: 21-12-2010 Doc no. 863013-VPS-PQM -C-DS-0002 Rev. 0 Page 2 of 16

Revision Revision description Prepared Checked Approved

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

 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

4.1 System Checklist ………………………………………………………………….......10

4.2 Mechanical Installation ………………………………………………………………..10

4.3 Electrical Installation …………………………………………………………………..10

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

5. PRE-COMMISSIONING PROCEDURE CHECKLIST …………………………………12

5.1 Air Duct ………………………………………………………………………………....12

5.2 Fans ………………………………………………………………………………….…12

5.3 Electrical Control Panel ……………………………………………………………....13

6. COMMISSIONING PROCEDURE ……………………………………………………...14

6.1 Operational Test ………………………………………………………………….…...14

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

7. APPENDICE ………………………………………………………………………….…...15

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

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

7.3 Commissioning 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

7.4 Commissioning 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
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
COMMISSIONING METHODE

1. Particulars

1.1 Ventilation Fan 3608 – VPS 01

Fan 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

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 .

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 As per Required: 10°C less Remarks

than Outside Temperature
temperature

1 35°C 25°C

2 34°C 24°C

3 33°C 23°C

4 32°C 22°C

5 31°C 21°C

6 30°C 20°C Fan will run at minimum

7 29°C 20°C Speed when the internal

8 28°C 20°C Temperature reaches 20°C

9 27°C 20°C

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.
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
 ITEM DESCRIPTION CHECK

5.0 PRE-COMMISSIONING PROCEDURE CHEKLIST

5.1 Air Duct
ITEM DESCRIPTION CHECK REMARKS
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
5.3 ELECTRICAL CONTROL PANEL
5.1.3 Check perforated plate cover insulation enclosure should be fix
5.3.1 Check termination cable on panel control, fans and accessories should
5.1.4 be tight
Check silencer box connection should be fix and tight

5.3.25.1.5 LineCheck
check discharge attenuator
cable termination connection
from should
control panel to be fixand
fans andaccessories
tight

5.3.3 Check marking cable after termination.

5.3.45.2 Fanscable line from control panel to motor fans after termination
Megger

5.3.55.2.1 Cleaning
Checkinside
and confirm
control installation
panel of fans.

5.3.65.2.2 Functional
Verify nameplate for fans.
check list VFD control panel VPS 01 (see table 9.1)

5.3.75.2.3 Functional
Check fan housing
check andControl
list VFD duct grounded
panel VPSshould betable
02 (see properly,
9.2) fix and tight.
5.2.4 The fans and the other duct work accessories have been correctly/properly
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.
7.0 APPENDICES
7.1 Functional Check list VFD Control Panel VPS 01 .

No. Description Check 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.

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.

No. Description Check 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.

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.

7.3. COMMISSIONING CHECKLIST AND RECORD FAN 3608 VPS 01

NO DESCRIPTION Check/Supply REMARKS

1 Power supply (24VDC / 110VAC / 220 VAC/ Other - state 400VAC

Start
2 Key Button & Operation Stop
Main Gen Stop.
Emergency Gen.
Stop
Overload
Motor O/C
Thermistor
7.3.1 Commissioning Record Fan 3608 - VPS 01 Open/High(3KΩ)
Thermistor
Item Description   Short/tooInsulation
low(50Ω) Resistant Remarks
External Sensor 33 33 33
3 Each Point function test with signalDesign
injection
Data Internal Sensor
Measured MΩ 24 Ω 23 22
Motor Speed
Fan Motor Power (Kw) 37.0   External Sensor
  30   30  30
Internal Sensor 21 20 19
Fan Motor Power supply Motor Speed
400/3/50
(V/ph/Hz)     29
  29
  29
External Sensor
Fan Motor Current (A) 66.8   Internal Sensor
  20   19  18
Motor Speed
7.3.2 Running Record Fan 3608 - VPS 01

Frequency Voltage Current Velocity Volume Noise (dbB)     

( Hz ) ( Volt ) ( Amp ) ( m/s ) ( Cmh ) 0-5m 0-10 m 0 - 15 m 0 - 20 m

                 

                 

                 

                 

                 

INSPECTION RESULT

PASS WITHIN LIMITS PASS BY CONCESSION RELEASED FOR

USE/DELIVERY
YES NO YES NO YES NO

TESTED BY APPROVED BY (if applicable)

7.4 COMMISSIONING CHECKLIST AND RECORD FAN 3616 VPS 02

NO Name & Signature
DESCRIPTION Date & Stamp Name & Signature REMARKS
Check/Supply Date & Stamp
7.4.1 Commissioning Record Fan 3616 - VPS 02
1 Power supply (24VDC / 110VAC / 220 VAC/ Other - state 400VAC
Item Description   Insulation
Start Resistant Remarks
7.4.2
2 Running Record Fan
Key Button & Operation 3616 - VPS 02 Stop
Design Data Measured MΩ Ω
Frequency Voltage Current Velocity Volume Main Gen Stop.
Noise (dbB)     
Fan Motor Power (Kw) 55.0   Emergency Gen.      
( Hz ) ( Volt ) ( Amp ) ( m/s ) ( Cmh ) 0 - 5 m Stop 0-10 m 0 - 15 m 0 - 20 m
Fan Motor Power supply Overload
      400/3/50
      Motor O/C      
(V/ph/Hz)        
Thermistor
                 
Fan Motor Current (A) 99.4   Open/High(3KΩ)      
Thermistor
                 
Short/too low(50Ω)
INSPECTION RESULT
        External
  Sensor   33   33  33
 
3 Each Point function test with signal injection
PASS WITHIN LIMITS Internal
PASS BY CONCESSION Sensor 24 RELEASED
23 FOR 22
           Motor Speed   USE/DELIVERY
   
YES NO YES External
NO Sensor 30 YES30 NO 30
Internal Sensor 21 20 19
Motor Speed
TESTED BY APPROVED BY (if applicable)
External Sensor 29 29 29
Internal Sensor 20 19 18
Motor Speed

Name & Signature Date & Stamp Name & Signature Date & Stamp
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 : ______________ ___________________ _________________