Since August 09 PowerQ has been involved in HVAC testing and commissioing in  following areas:

• 3x 57 Storey hotel  towers with about 3000 rooms
• Casino and retail area

PowerQ has provided caliberated instrument and experianced tesm of enginners, document controller and technicians to test thousands of equipments . PowerQ have performed T&C of life  safety system such as staircase pressurisation, exhaust ventilation IAQ system for casino, AHU and FCU system for hotels, casino and  retail area. PowerQ is part of commissioing team lead by MBS and its consultants and contractors.
The finetuning of T&C  work shall continue  till 3rd quarter of this 2010 and PowerQ is ensuring to provide a comfortable, safe and efficient facility.

Our enginners  reviewed the installtion drawing,  alignment and factory report and conducted  Vibration verification measurement on  AHU and Chiller Compressor and Wall Mounted Condenser  Axial Fans  at following location :

Compressor

Condenser  Fans

AHU blower 

The result of measuremnt was use to mitigate the excessive vibration levels and helped to avid any failure of critical system while the vessel is performing offshore  production.

2. Project Description

Two GTGs, one duty and one standby, are provided at CPP as main power generation.  CPP and WP are steel structures of which all major structural components are intended welded firmly to deck. The earth bars are intended to be bonded to platform legs.

 3. Objective and Scope

This review was intended to address the need for lightning protection and electronic surge protection on CPP  and WP. PowerQ Technology Pte Ltd was asked by EPC contractor to carry out a comprehensive evaluation of  design  and existing design of Lightning and earthing Protection System and make practical recommendation considering that the construction is ongoing.

 The objectives of the lightning protection review study was to

• Review the design and  recommendation 
  • To review  whether external lightning  terminal are required
  • To review extend of SPD,s necessary and required
• Review the proposed  lightning protection system against standards
• Suggest suitable practical recommendation based on current project status.

 To address objectives PowerQ had undertaken following tasks:

 a)     Review of Design and specifications

b)    Review Offshore code and standard

c)     Review of various lightning protection measures

d)     Review of current practice in offshore installation

 The intent of review is to provide practical  guidance and not to emphasis on theory of lightning.  PowerQ evaluated several offshore installtion design and provided the best implementable Option to adopt and provide sufficient justifications for the recommendation thus meeting codes but minimising cost of installtion.

The work was performed in 2010 and shall be under continious review . PowerQ is also providing Power System Studies for this project and shall be providing services to client till 2011 as per contract.

PowerQ commissioing enginners discussed the operation with the clients enginners, collected equipement data , drawings, specification and reviewed physical system and  prepared O& M Manuals comprising of   three sections  SYSTEM DESCRIPTION ,  SYSTEM OPERATION  and  SYSTEM MAINTENENCE. Extensive used of flowchart and simplified layout drawing was made to easy understanding.

Special emphasis was laid to safe operation and energy efficient O&M  procedure. The manual was produced in hardcopy and indexed pdf softcopy. The information in manual shall be further used for scheduling predictive  maintainence and RCM.

A new underground MRT line called as circle line is being constructed in Singapore. As certified testing company PowerQ worked with SETSCO services and assited the main contractor to conduct a crucial testing by pressuring the entire building like a balloon.  The purpose of the ATT is to provide an indication if the Civil Defense Shelter and all its mechanical penetrations and closure devices are airtight against the penetration of air from outside. 

One of the most challenginning part of the work waas erfomed by construction team by sealing any gaps in thousand of sqare meter of serface area including all the penetrations for utilities and human and train  access though tunnel. This test allowed  for the easy detection of leaks from Blast Doors, Blast Valves Sleeves/Frames, Protective/Hardened Structures, Sealing Devices and etce. The entire volume 4 storey structure measuring more than 10,000 sq m was presssurised with a fan with caliberated venturi for measuremnt of flow. The flow and pressure was monitored over duration of test with data loggers and digital instrumentation specially configured for test. Hundreds of meter of sensor tubing was run and the pressure drop was compensated by applying correction factors in loggers placed on various floors .

PowerQ conducted IOPT and ATT tests, conducted within the protected bounds of the Concourse, Platform and Underplatform Levels. The test was witnessed by authorities and passed in first atttemps thanks to extensive preparation, planning and coordination works done by hundreds of staff. Passing of this milestaone   test conducted in 2009 and allowed the JV main contractor  to continue the construction process.

PowerQ has conducted similar tests for facilities such as Isolation and OT rooms in hospitals, Blast proof rooms in oil rigs ,  Halon Pressurised room in Data Centres and BSL negative pressurised rooms in animal holding facilities/Vivariums  and BSL labs .

Enginners from PowerQ installed EMF data logger  to measure and monitor with data logger to generate a clear picture of EMF emissions in the areas over time and capture any peak values.  The data was recorded for several weeks and at interval of 1 mnute undered varied operating condion . PowerQ provided  observation status and re-measured EMF  after the proposed measures had been implemented to analyze the collective information of EMF interference bymminimum and maximum field strength readings.

Monitoring at LV SBB SAP/CO

The inrush current was recorded at individual motors was performed at using Fluke recorder. The data collected has been analyzed and checked against IEEE 519 standards.

Following recommendation implemented to prevent he tripping problem:

1. Reset setting ABB SPAJ relay characteristic of ACB characteristic. Previously the relay tripping ACB at SSB SAP/CO incomer is set lower that MCC board incomer, which was suspected to have contributed to the occurrence of nuisance tripping at incomer due to lack of discrimination.
2. Resetting  and programming the Soft Starter to prevent High Inrush Current. The hooked-up power monitor had captured short-duration inrush as high as 600% (e.g.  Main Acid Pump 90kW has approximately full load current of 160 A but start current of 971 A while for BL 402 the full load current is 317 A while start inrush is as high as 974A), If plant is already running and a large motor such as P408 or BL 402 is restarted possibility of tripping will be there.

To avoid this scenario the soft starter was recommended be set to limit current to 300% and/or ramp time of the soft starter should be increased. Generally a ramp time of 8 second should be sufficient to limit inrush below 300%. This was be done in confirmation with process requirements. It is recommended that the correct setting of soft starter shall be implemented so as to reduce chances of tripping due to starting current.

Existing and Recommended Settings for Overcurrent Relay

Piping Facility

The objective of the work was to:
General visual inspection of existing hot and cold service water piping to locate any abnormalities such as leaks cracks, pits, and general wall thinning without removing the piping from service.
Review condition of supports and hangers for hot and cold service water piping
Perform thickness tests at at about 50 locations.
Identify any anomalies

The following tasks were carried out:

1. Briefing Meeting and Discussion
2. Brief Review of specification and construction drawing to identify and establish routing
3. Site verification
   An on-site inspection of all the piping services equipment at Plant and production area was carried out. Where applicable we refer to relevant codes such as ANSI/API570 (Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems) for inspecting the piping

• 100% visual check at practically accessible areas to locate any abnormalities such as leaks cracks, pits, and abnormal condition of support & hangers without removing the piping from service.
• Visual inspection of the cut out piping where leakage occurred as also carried out and separate condition testing was performed in Japan by Taikisha. Visual inspection shows no internal deposit or pitting of copper pipe.
• Random Thickness test was carried out by Certified NDT professional at the location identified by PowerQ inspection team. This measuring system is employed to inspect the pipelines Corrosion reduces wall thickness and may eventually lead to cracking with potentially disastrous consequences.
• Visual pipe line inspection was be aided by magnifying glass, measuring tape, veneer calliper, mirror, high beam torch light and a digital camera. Identification shall be given to tested locations and will be also referred on relevant drawing.

Finding and Recommendations
Some anomalies related to installation and mechanical damage to piping as are identified. There were spot of water mark on ceiling board found which is probably due to condensation water droppings. There were no leakages found on copper piping.

The thickness testing should be viewed as first step to determine general condition water piping. It is found that there is no appreciable loss of wall thickness the copper pipe are not internal corroded.

It was found that generally the fire-protection system conformed to appropriate standards in type and design to meet NFPA code. However, the survey found some inadequacies in the condition and status of the system, which were detailed out in the survey report.

Control valves or individual isolation valves accidentally closed
One of the most common faults possible; the fire protection system is fully operational and in good condition, except that the water supply is accidentally turned off.
It is understood from Lexmark that the control valves are only turned on when an alarm signal is received. This is strongly not recommended since the sprinklers are highly effective during initial stages of a fire and the immediacy of sprinkler response must not be compromised.
In this survey, individual isolation valves are observed not strapped in the open position, which may invite tampering in the future. It is strongly recommended that all valves be to be strapped and padlocked in the open position.

Sprinkler pumps installation
Pressure Relief Valve not operating.
The pressure relief valve (PRV) at the Circuit Assembly Plant is not working. In an unlikely scenario, the pressure in the sprinkler system may build up beyond the range of the sprinkler pump recommended operating range, resulting in a drastic dip in pressure and little water at sprinkler heads.

Inspector Test Valve Assembly
The relief valve at the inspector test valve assembly is not opened. This may result in excessive pressure buildup within the sprinkler system.

Fire and Jockey pump pressure setting
The fire pump, when started by pressure drop should be arranged to ensure that the first fire pump to operate does not cause water hammer due to the system pressure being allowed to drop too low. When a fire pump starts the pressure will be equal to its churn pressure, this is typically between 101% and 140% of the rated pressure. Jockey pumps should be arranged to cut-in at the fire pump churn pressure and cut-out at the pump churn pressure plus 10 psi. The first fire pump should operate at 5 psi less than the pump churn pressure. Additional pumps should operate at 10 psi increments. It was also recommended that a confirmation shall be done prior to increasing the system pressure that the system is capable of maintaining that pressure.

Other faults recommended to be rectified in the next preventive maintenance period were also advised to client.

Problem
It was found that some areas in the data centre were relatively hot and the operator was concerned about the situation. Other areas of the DC were reportedly having acceptable temperature. At the same time it was reported that the CHW flow rate at main header serving data centre had dropped. The room temperature set by the point design in the DC was 22.5 0C .

The objective of the audit was to find out if installed equipment was working as intended and to identify any areas in the air-conditioning distribution system that could enhance the system performance.

Approach
PowerQ conducted audit by performing the following tasks:

1. Performed cooling capacity calculation based on 525 watts/m2 load.
2. Physical inspection of CRAU units and airflow distribution in data centre.
3. Physical test on CRAU to ascertain performance. The test results were summarised while the performance test of the CRAU was also undertaken
4. 24 Hour room temperature monitoring was also carried out at various spots in DC.
5. The actual cooling capacity with the demand (525 watts/sqm) was compared with the design load.

Observation
The audit revealed that several actions needed to be undertaken to improve and recover the DC temperature requirements. The following were the key observations:

1. Measurements showed that the actual performance of the equipment was above the demand of 525W/sqm. Total sensible cooling capacity computed based on measurement was 681 w/m2 as against the design of 732 w/m2.
2. There was a loss of capacity of CRAU 43 (about 16 Tr during the time when the problem was identified, this capacity was partially compensated by a temporary FCU). Post rectification this capacity’s now again available which will further enhance cooling capacity
3. There was loss of capacity of CRAU 39 (This was confirmed by the fact that the supply air temperature was 210C and the pressure drop across coil was only 1 psi (compared to 3-4 psi for similar capacity CRAC units i.e. CRAU 38 and CRAU 40) indicating a very low or no flow. Once this CRAU 39 is rectified the additional cooling capacity would be available which will further enhance cooling capacity
4. The temperature data logging at three locations in DC showed that at two locations the temperature was maintained. Only at location #03-31 (Area A close to non performing CRAU 43) the average temperature was 23.8 which was higher than the required (22.50 C).
5. There was some exfiltration of air through the various doors in DC to air-conditioned corridor This explained why the total supply volume was higher than the return air volume at CRAU.

Recommendations
Following were the main recommended actions in the order of priority:

1. Rectify CHW flow problem at CRAU . (Post audit -This problem was rectified and PowerQ re-tested the CHW flow of the unit to confirm the CHW flow requirements and unit is the performing satisfactorily.)
2. Check for any underflow blockades for air flow to Improve air distribution in area served by CRAU by closing undesirable openings and providing an under floor partition and to prevent air loss to other areas.
3. Check and tighten the loose belt (if any) of CRAU supplying lower airflow. (Consider this CRAU 34 and 35 are of same design and installed in same room CRAU 34 is having FLA of 5.5 A while CRAU 34 has FLA of 10.2 A indicating possible belt slippage at CRAU 340.
4. Provide door seals at DC door to reduce exfiltration of air.
5. Install the industry standard pressure test port for flow measurement.
6. Consider to lower the set point for CRAU 43,44 and 45 (by 1-20C). It is noted that the Return air temperature sensor measure lower temperature than is actually in area .