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SOD-08556 - LSP-005 -FAT-005..
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FAT 16 June 2013 Page 1 of 24
FACTORY ACCEPTANCE TESTING
Life Support Package
LSP-005
DOCUMENT INFORMATION
Doc No: LSP-005-FAT-2015 Srl No: LSP-005
Revision B Mag file
Issued 02-02-2015. Author VK
Unique CLIENT
FAT 16 June 2013 Page 2 of 24
Contents 1. Introduction ........................................................................................................................................................ 4
1.1 Scope ............................................................................................................................................................ 4
1.2 Objective ....................................................................................................................................................... 4
1.3 Definitions..................................................................................................................................................... 4
1.4 Responsibilities ............................................................................................................................................. 4
1.5 Reference Documents .................................................................................................................................. 4
2. GENERAL ............................................................................................................................................................. 5
2. 1 Operations manual ...................................................................................................................................... 5
2.2 Cleanliness of System ................................................................................................................................... 5
2.3 Permanent marking of equipment ............................................................................................................... 6
2.4 Calibration of essential gauges and clocks ................................................................................................... 6
2.5 Structural integrity and corrosion status of system ..................................................................................... 6
2.6 Gas distribution system ................................................................................................................................ 7
2.7 ECU-1 (ECU-C-101-010) ..................................................................................................................... 8
2.7-1 QC Checks ............................................................................................................................................. 8
2.7-2 Pipe Pressure leak Testing ................................................................................................................... 9
2.7-3 Function testing .................................................................................................................................. 10
2.7-4 Pump Electrical Testing ...................................................................................................................... 11
2.7-5 Heater Element Electrical Testing ...................................................................................................... 11
2.7-6 Electrical Function Testing .................................................................................................................. 12
2.8 ECU-2 (ECU-C-101-011) ................................................................................................................... 13
2.8-1 QC Checks ........................................................................................................................................... 13
2.8-2 Pipe Pressure leak Testing ................................................................................................................. 14
2.8-3 Function testing .................................................................................................................................. 15
2.8-4 Pump Electrical Testing ...................................................................................................................... 16
2.8-5 Heater Element Electrical Testing ...................................................................................................... 16
2.8-6 Electrical Function Testing .................................................................................................................. 17
2.9 IMCA Testing & Reports Required ....................................................................................................... 18
2.10 Main electrical supplies ....................................................................................................................... 19
2.11 Communication systems ...................................................................................................................... 19
FAT 16 June 2013 Page 3 of 24
2.12. Analyzer Calibration. ............................................................................................................................... 20
2.13. Fire Protection .................................................................................................................................. 20
2.14. Internal Electrical .............................................................................................................................. 20
2.15. General Safety Audit of System ........................................................................................................ 21
3. PRESSURE TESTING ........................................................................................................................................... 22
3.1 Piping pressure testing ............................................................................................................................... 22
3.2. Hose components pressure test. ............................................................................................................... 23
4. Control Measures ........................................................................................................................................... 24
FAT 16 June 2013 Page 4 of 24
1. Introduction
This FAT has been compiled to define testing requirements for maintaining the certification of the portable chamber control (Life Support Package). It may also form the basis of the certificate that is to be issued upon successful completion of the testing and inspection listed herein. Only a nominated competent person may sign for the completion of a task detailed in this manual. Before doing so, section 1.1 must be completed by the person signing. IMPORTANT This manual is used for each periodic survey. During each year, the equipment comprising the portable chamber control may change. Always check that the copy being used has been revised for the year and type of survey being performed.
1.1 Scope The scope of this Factory Acceptance Test (FAT) covers the testing of all equipment that is contained in the Life Support System ( LSP 005) as defined by the client approved manufacturing design data provided with the FAT.
1.2 Objective To Ensure that the LSP design & Operation meets the contractual requirements.
1.3 Definitions The following terms and abbreviations are used throughout this manual and their meaning will be as defined below. Classification Society Det Norske Veritas (DNV) ECU Environmental Control Unit HRV Hyperbaric Rescue Vessel SPP Sound Powered Phone SWL Safe Working Load.
1.4 Responsibilities Unique System shall prepare the FAT and carry out all the testing. The Client Representative shall approve the FAT and witness all the testing.
1.5 Reference Documents DNV-RP-E403- standard for hyperbaric evacuation system IMO Code of Safety for Diving System IMCA Applicable code of practice for Life support system Client Approved design data-
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FAT 16 June 2013 Page 5 of 24
2. GENERAL
2. 1 Operations manual
Inspection Accept/Reject Reason
1. System Operation & maintenance manual shall be reviewed by the
DNV Surveyor.
2. Planned maintenance system shall be reviewed by the DNV surveyor
3. Safety valves, Gauges, Alarms and piping should be registered in
planned maintenance system for record keeping
4. Any portable / temporarily installed equipment used as part of the
portable chamber control should also be maintained by the operator
/ owner.
2.2 Cleanliness of System
Inspection Accept/Reject Reason
1. Internal & External visual survey shall be performed by the surveyor
to assure the cleanliness and suitability of the system.
2. Attention should be paid to ensure the contamination , damages, or
any external defects.
3. All internal equipment and control panel should be free of corrosion
and any other debris.
4. An oxygen cleaning procedure should be in place for the cleaning of new pipe work that is used for breathing- PRO-0013 (DNV approved)
5. Cleaning report should be reviewed by the surveyor
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2.3 Permanent marking of equipment
Inspection Accept/Reject Reason
1. Check for permanent marking of electrical cables, strips, valves and
fittings penetrators, and regulators
2. The marked equipment should be traceable through the Planned Maintenance System. .
3. Ensure all the markings on the control panel are in place.
2.4 Calibration of essential gauges and clocks
Inspection Accept/Reject Reason
1. All Gauges should be tested as per IMCA D 018
2. Depth gauges & life support Gauges should be calibrated by a
qualified competent person on a 6 monthly basis and calibration
equipment should be traceable to IMCA
3. Ensure the serial number and certificate numbers and test date labels are available on the gauges
2.5 Structural integrity and corrosion status of system
Inspection Accept/Reject Reason
1. The container should be made as per DNV rules DNV 2.7-1 and
review the DNV certificate of the container.
2. Attention should be made to maintenance, possible damage and
serious corrosion
3. Corrosion inspection shall be done internally & externally on all the equipment inside the LSP container
4. Perform a thorough examination the lifting slings and shackles to ensure they meet the SWL.
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FAT 16 June 2013 Page 7 of 24
2.6 Gas distribution system
Inspection Accept/Reject Reason
1. Valves on the control panels should turn smoothly. Care must be
taken to ensure no pressure is behind the valves.
2. The HP oxygen control system should not be fitted with quarter turn valves.
3. Ensure all valves and piping is marked and connected correctly
4 Ensure the pressure testing of the panels are satisfactory and review
the certificate.
.
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2.7 ECU-1 (ECU-C-101-010) ECU Testing shall include the following.
2.7-1 QC Checks
Inspection Accept/Reject Reason
1. Ensure frame is Painted and in good condition
2. Complete a visual inspection of the ECU and ensure all areas are free
of dirt, bad workmanship or scratches.
3. Ensure all bolts where used on vibration applications are nylock or
have spring washers.
4. Ensure all lifting arrangements are full safety bolts with split pin and
castle nut. N/A
5. Ensure all supplied nuts are replaced with stainless steel, including
nuts, etc.
6. Inspect filter after use and ensure it is clean before packing.
7. Hazard warning signs must be displayed on all potentially dangerous
areas. (Electrical boxes, Moving parts and any Hot parts)
8. All valves to be labeled
9. All inlet and outlet to be labeled with function
10. A nameplate must be a fixed to the product.
11. Ensure all valves are accessible and operate easily.
12. Ensure all valve operate fully open and fully closed.
13. Ensure all valves are labeled correctly for function.
14. Ensure all exhaust pipe-work such as relief valve vents, etc vent in to
an enclosed space or safe place. (Never into a person face or body)
15. Ensure pipe clamps are secure.
16. Ensure all pressure gauges are filled with glycerine.
17. Inspect insulation and ensure all areas are covered. Ensure insulation
is neat and tidy.
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FAT 16 June 2013 Page 9 of 24
Inspection
Accept/Reject
Reason
19. Control switch board securely fastened to the frame.
20. All cabling is fastened and safely conducted within the product.
21. Drawing of the electrical wiring is inside. Record drawing no and revision.
DWG No. USD-E-14-1295 Rev B and supply USD-E-14-1271 Rev C
22. All wires are visibly in good condition
23. All switches relay and blocks are numbered.
24. All panel wires are numbered
25. With the power OFF at the main circuit breaker and disconnected,
conduct a panel wire pull test; ensure all wires are installed tightly.
26. Ensure the electrical switches and dials do no protrude into walkways.
2.7-2 Pipe Pressure leak Testing All leak tests are to be done at the MAWP of the piping system under test
Pipe number/description Operating pressure (bar) Pass/Fail
1. HOT Supply 3 Bar
2. HOT Return 3 Bar
3. COLD Supply 3 Bar
4. COLD Return 3 Bar
5. HOT Tank Surface
6. COLD Tank Surface
7. COLD Chiller gas delivery Leak test at WP
8. COLD Chiller gas suction Leak test at WP
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2.7-3 Function testing
Test Method Required result Result obtained Accept/
Reject
1. Check flow rate of water, Minimum flow of both the
pumps - 25l/min
2. Record Ambient Temperature These values are for future
comparison
Ambient
Temp:
3. Verify pt100 temperature readings. +/-1C Difference
4.
Function test level switch while filling
tank Functioning
5. Turn on pumps, check direction and
pressure Clockwise, +/-2.5bar@ 50Hz
HOT WATER
PUMP:
COLD WATER
PUMP:
6. Function test flow switches, turn
pumps on and off 3 times
3 successful indications
required
7. Note the time taken to reach the temp
from first reading to set temperature
Cold water- 20C to 6C
Hot Water- 49.5C to 60 C
9.
Run Chiller on cooling, set cooling
temp at 6C (while running the
resistance heater)
Off @ 6C; On @ 6.5 C
11. Leak test delivery gauge on chiller. No Leaks
12. Test Standby Heating Element check
cut out temperature. Off @ 60C; On @ 59.9 C
13. Run system for a total test time of 4
hours without fault 4 hours run, no faults
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2.7-4 Pump Electrical Testing
Megger and Continuity testing
All megger testing is to be done at 500V for a minimum of 30 seconds per line. A minimum ohm reading of 1 Mega Ohm or more should be obtained. Remove all star point connection or links for this test.
Electrical motor testing
Cold water pump SN:0409133905 Megger result Continuity result
1. U1 V1
2. V1 W1
3. W1 U1
Hot water pump SN: 0409133913
1. U1 V1
2. V1 W1
3. W1 U1
2.7-5 Heater Element Electrical Testing Resistance element Megger result Continuity result
1. Heater element- EL1 El2
2. Heater element- EL2 El3
3. Heater element- EL3 El1
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2.7-6 Electrical Function Testing
Test Method Required result
Result
obtained Accept/Reject
1. Confirm Gefran Temperature Controller parameters
are correct
Control Parameters
setting
2. Confirm The chiller Cold Controller parameters are
correct
Control Parameters
setting
3.
Confirm overload settings for the overloads is
set to the Amp ratings on the motors
nameplate:
O/L-1 9. Amp
O/L-2 9 Amp
O/L-3 2.3 Amp
O/L-4 2.3 Amp
4.
Function test Over Temp Controller to ensure that the
Heater Element will de-energize when the tank
temperature value exceeds that of the set value on
the Over-Temp Controller.
1C
5. Test that when the chiller water tank level is low
The Tank Water level
light will be on
The Manual Heater
Element Contactor will
not energize.
6. Cold water pump Amp reading 2 Amp @ 50Hz (0.2)
7. Cold water chiller Amp reading 5.5 Amp @ 50Hz ( 2)
8. HOT water pump Amp reading 2.0Amp @ 50Hz (0.5)
9. Heater Element Amp Reading 7.5Amp @ 50Hz (0.5)
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FAT 16 June 2013 Page 13 of 24
2.8 ECU-2 (ECU-C-101-011) ECU Testing shall include the following.
2.8-1 QC Checks
Inspection Accept/Reject Reason
1. Ensure frame is Painted and in good condition
2. Complete a visual inspection of the ECU and ensure all areas are free
of dirt, bad workmanship or scratches.
3. Ensure all bolts where used on vibration applications are nylock or
have spring washers.
4. Ensure all lifting arrangements are full safety bolts with split pin and
castle nut. N/A
5. Ensure all supplied nuts are replaced with stainless steel, including
nuts, etc.
6. Inspect filter after use and ensure it is clean before packing.
7. Hazard warning signs must be displayed on all potentially dangerous
areas. (Electrical boxes, Moving parts and any Hot parts)
8. All valves to be labeled
9. All inlet and outlet to be labeled with function
10. A nameplate must be a fixed to the product.
11. Ensure all valves are accessible and operate easily.
12. Ensure all valve operate fully open and fully closed.
13. Ensure all valves are labeled correctly for function.
14. Ensure all exhaust pipe-work such as relief valve vents, etc vent in to
an enclosed space or safe place. (Never into a person face or body)
15. Ensure pipe clamps are secure.
16. Ensure all pressure gauges are filled with glycerine.
17. Inspect insulation and ensure all areas are covered. Ensure insulation
is neat and tidy.
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FAT 16 June 2013 Page 14 of 24
Inspection
Accept/Reject
Reason
19. Control switch board securely fastened to the frame.
20. All cabling is fastened and safely conducted within the product.
21. Drawing of the electrical wiring is inside. Record drawing no and revision.
DWG No. USD-E-14-1295 Rev B and supply USD-E-14-1271 Rev C
22. All wires are visibly in good condition
23. All switches relay and blocks are numbered.
24. All panel wires are numbered
25. With the power OFF at the main circuit breaker and disconnected,
conduct a panel wire pull test; ensure all wires are installed tightly.
26. Ensure the electrical switches and dials do no protrude into walkways.
2.8-2 Pipe Pressure leak Testing All leak tests are to be done at the MAWP of the piping system under test
Pipe number/description Operating pressure (bar) Pass/Fail
1. HOT Supply 3 Bar
2. HOT Return 3 Bar
3. COLD Supply 3 Bar
4. COLD Return 3 Bar
5. HOT Tank Surface
6. COLD Tank Surface
7. COLD Chiller gas delivery Leak test at WP
8. COLD Chiller gas suction Leak test at WP
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2.8-3 Function testing
Test Method Required result Result obtained Accept/
Reject
1. Check flow rate of cooling water, Minimum flow of both the
pump -25l/min
2. Record Ambient Temperature These values are for future
comparison
Ambient
Temp:
3. Verify pt100 temperature readings. +/-1C Difference
4.
Function test level switch while filling
tank Functioning
5. Turn on pumps, check direction and
pressure Clockwise, +/-2.5bar@ 50Hz
HOT WATER
PUMP:
COLD WATER
PUMP:
6. Function test flow switches, turn
pumps on and off 3 times
3 successful indications
required
7. Note the time taken to reach the temp
from first reading to set temperature
Cold water- 18C to 6C
Hot Water- 53.5C to 64 C
9.
Run Chiller on cooling, set cooling
temp at 6C (while running the
resistance heater)
Off @ 6C; On @ 8 C
11. Leak test delivery gauge on chiller, No Leaks
12. Test Standby Heating Element check
cut out temperature. Off @ 60C; On @ 59 C
13. Run system for a total test time of 4
hours without fault 4 hours run, no faults
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FAT 16 June 2013 Page 16 of 24
2.8-4 Pump Electrical Testing
Megger and Continuity testing
All megger testing is to be done at 500V for a minimum of 30 seconds per line. A minimum ohm reading of 1 Mega Ohm or more should be obtained. Remove all star point connection or links for this test.
Electrical motor testing
Cold water pump SN:0409133905 Megger result Continuity result
1. U1 V1
2. V1 W1
3. W1 U1
Hot water pump SN: 0409133913
1. U1 V1
2. V1 W1
3. W1 U1
2.8-5 Heater Element Electrical Testing Resistance element Megger result Continuity result
1. Heater element- EL1 El2
2. Heater element- EL2 El3
3. Heater element- EL3 El1
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FAT 16 June 2013 Page 17 of 24
2.8-6 Electrical Function Testing
Test Method Required result
Result
obtained Accept/Reject
1. Confirm Gefran Temperature Controller parameters
are correct
Control Parameters
setting
2. Confirm The chiller Cold Controller parameters are
correct
Control Parameters
setting
3.
Confirm overload settings for the overloads is
set to the Amp ratings on the motors
nameplate:
O/L-1 9. Amp
O/L-2 9 Amp
O/L-3 2.3 Amp
O/L-4 2.3 Amp
4.
Function test Over Temp Controller to ensure that the
Heater Element will de-energize when the tank
temperature value exceeds that of the set value on
the Over-Temp Controller.
1C
5. Measure Amps drawn on resistance heater- 6kW 7.5 AMPS(0.5)
6. Test that when the chiller water tank level is low
The Tank Water level
light will be on
The Manual Heater
Element Contactor will
not energize.
7. Cold water pump Amp reading 2 Amp @ 50Hz (0.2)
8. Cold water chiller Amp reading 5.5 Amp @ 50Hz ( 2)
10. HOT water pump Amp reading 2.0Amp @ 50Hz (0.5)
11. Heater Element Amp Reading 7.5Amp @ 50Hz (0.5)
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2.9 IMCA Testing & Reports Required
IMCA SECTION PARAGRAPH DESCRIPTION
Report Number(s)
IMCA D024, Section 16 6.8 Electrical Protection UDp-14-64184,64185,64186
IMCA D024, Section 16 6.9 Electrical testing UDp-14-64184,64185,64186
IMCA D024, Section 16 6.10 Emergency Electrical testing UDp-14-64184,64185,64186
IMCA D024, Section 16 8.5 BA Testing function test UDP-14-64473
IMCA D024, Section 16 8.6 BA Cylinder gas leak test UDP-14-64474
IMCA D024, Section 16 8.7 BA Cylinder Over pressure test 12-36753-1
IMCA D024, Section 16 8.10 Communication testing UDP-14-64187,64188
IMCA D024, Section 16 8.22 Communication testing UDP-14-64187,64188
IMCA D024, Section 16 8.31 Pipe work over pressure test UDP-14-64216,64217,64218
IMCA D024, Section 16 8.32 Pipe work Visual Inspection UDP-14-64467,64468,64469
IMCA D024, Section 16 8.33 Pipe work gas leak test UDP-14-64467,64468,64469
IMCA D024, Section 16 8.35 Relief valve visual examination UDP-14-64191,64192,-
64193,64194, 64195
IMCA D024, Section 16 8.36 Relief valve Function & gas leak test UDP-14-64191,64192,-
64193,64194, 64195
IMCA D024, Section 16 8.38 Electrical Equipment Function ,
Continuity & resistance check UDp-14-64184,64185,64186
IMCA D024, Section 16 8.48 Analyzer function test UDP-14-64182, 64183
IMCA D024, Section 16 8.49 Alarm function test UDP-14-64182, 64183
IMCA D024, Section 16 9.3 ECU Function test UDP-14-64210, 64214
IMCA D024, Section 16 11.5 Hose component Over pressure test UDP-14-64170,171,173,175
IMCA D024, Section 16 11.5 Hose component Visual examination
check UDP-14-64170,171,173,175
IMCA D024, Section 16 11.5 Hose component Gas leak test UDP-14-64170,171,173,175
IMCA D024, Section 16 12.6 Electrical Cable continuity and
resistance check
IMCA D024, Section 16 12.7 Hose component Over pressure test UDP-14-64169,172,174,176,
177,178,179, 180,181,182,183
IMCA D024, Section 16 12.8 Hose component Visual inspection UDP-14-64169,172,174,176,
177,178,179, 180,181,182,183
IMCA D024, Section 16 12.8 Hose component gas leak test UDP-14-64169,172,174,176,
177,178,179, 180,181,182,183
IMCA D024, Section 16 12.2 Fire fighting testing 158561/1 , 158561/2
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2.10 Main electrical supplies
Inspection Accept/Reject Reason
1. Main power supplies for the following are to be inspected and tested: Megger
2. Internal power outlets MEGGER CONTINUITY
3. Monitoring devices
4. Control Panel
5. SPHL Cable- Comms-1
6. SPHL Cable- Comms-2
7. SPHL Cable- Power-1
8. SPHL Cable- Power-2
9. Monitor coaxial cable- Core
Monitor coaxial cable- Coax
2.11 Communication systems
Inspection Accept/Reject Reason
1.
Test the main communications 3 Diver Rack mound communication. It should include, Channel -1 communication testing with test speaker Channel -2 communication testing with test speaker Channel -3 communication testing with test speaker
Accept
2. The test should include the use of the sound powered phone and headsets.
Accept
3. Video Monitor shall be tested with a test camera in order to function test
Accept
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2.12. Analyzer Calibration.
Inspection Accept/Reject Reason
1. All the analyzer should be function tested in order to ensure the functioning of the device
2. Analyzers should be calibrated for their required gas sensor with calibrated gas.
3. DNV Surveyor shall review the certificate for the analyzers
2.13. Fire Protection
Inspection Accept/Reject Reason
1. Suitable portable fire extinguisher should be placed inside the system for the fire protection.
2. Fill level of the fire extinguisher need to be checked and confirmed.
3. The cylinder need to be checked for any leaks
4 Ensure the testing of the fire extinguisher is in date and review the certificate.
2.14. Internal Electrical Test internal lighting system with normal power
SYSTEM POWER OPERATIONAL Comments Internal Lighting Normal Electrical power
Emergency Electrical Power
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2.15. General Safety Audit of System
Equipment/System Requirement Findings
Walkways Clear Non Slip
Sea fastenings General equipment verified as sea fastened adequately
Electrical supply Correctly connected to board, adequate rating of board, cables protected from damage
Gas supply Hoses protected from damage Hoses out of the direct sun or covered
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3. PRESSURE TESTING
3.1 Piping pressure testing
Pressure testing is to be carried out on all relevant components the following Table gives indicative test pressures for typical components of the control panel & system.
ITEM Hydro Testing
(Review)
Gas Leak Testing
(Witnessed )
Duration- 1 hour
Pass/ Fail
Mix-1 In
Mix-1 Out
Mix-2 in
Mix-2 out
O2 Injection in
O2 Injection Out
Bibs in
Bibs out
Depth in
Sample in
Panel Exhaust
Flow test need to carried out with full working pressure of the system along with the whips and hoses Visual Examination: E External; I Internal. All above to be witnessed by DNV surveyor. Hydro-test covers thorough visual inspection, internally. Leak test with minimum 100% Nitrogen. Note fire risk with air at high pressure. When testing gauges ensure the gauge is not pressurized above maximum pressure.
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3.2. Hose components pressure test.
Item Hydro
Testing
Length Working
Pressure
Gas Leak
Testing
(Witnessed)
1 hour
Hydro test
(Witnessed)
Pass/ Fail
Depth
Sample
O2 Make-up In
Out
BIBS Supply In
Out
Mix-1 In
Out
Mix-2 In
Out
Exhaust
Hot Water Supply In
Hot Water Return Out
Cold Water Supply In
Cold Water Return Out
- Flow test from the panel through the interconnecting hoses with 200 bar on line. - Hot and cold water flow test through hoses - Pressure and leak test of the hoses
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FAT 16 June 2013 Page 24 of 24
4. Control Measures The following are typical controls which may be required from the task risk assessment
Inspection Accept/Reject Reason
1. Access restrictions and barriers
2. Hearing protection for gas testing
3. Eye protection
4. Hose and whip securing
5. Permit to work to be raised for the test
6. Provision of suitable ventilation in the area of the pressure test
7. Provision of suitable escape routes for test personnel
8. Provision of oil contamination cleanup materials if the test medium is oil
9. Ensuring that a failure during the pressure test will not cause damage to the surrounding area (water leakage causing damage to surrounding area due to poor drainage or gas escape causing localized
overpressure)
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