IR#04 010320140100 HACE 03-02-2015.doc

ENERGY ENGINEERING INERNATIONAL FACILITIES SERVICES L.L.C

INSPECTION REPORTReport No: IR04 Revision: 00 Date: 05-02-2015 Page : 1 of 15

INITIAL REPORT INTERIM REPORT FINAL REPORT

CONTRACT DESCRIPTION

Client SAUDI OGER LIMITED Project Contract No. Not Available

Project KACWC Surveillance Agency ENERGY ENGINEERING

B.I. Number 10-07575

Attention Mr. Jose Francisco

Email [email protected]

Copies [email protected]

PO No 01/03/2014/01/00 Agency Reference No.

PRIME SUPPLIER SUB-SUPPLIER

Company HACE Company None

Address P.O. Box : 2625, Riyadh Address None

Representative None Representative None

Purchase Order No. 01/03/2014/01/00 Purchase Order No. None

Telephone 00966-11-2651500 Telephone None

Fax/Email: 00966-11-2651521 Fax/Email: None

Material Description FCUs Material Description None

INSPECTION INFORMATION

Purpose of Visit Testing of FCUs as per UL1995 Standard

Inspection Lot No. Not Applicable P.O Status COMPLETE IN-COMPLETE

Date(s) of Visit/s 03-02-2015 Date of Last visit Jan 27th 2015

Next Scheduled Visit TBA Frequency of DAILY WEEKLY MONTHLY

Visits

Energy Engineering

Coordinator

Ms. Rithu Koshy Coordinator number

+971 6 7419328 Ext: 220

Technical Specialist Zubair Ahmad SAP No. 70007842

INSPECTION DISPOSITION: Accept Nonconformance(s) identified Place on Hold Other Explain ( Refer the section “ INSPECTION SUMMARY & CONCLUSION”

INSPECTION SUMMARY AND CONCLUSION :

It was an inspection notification for Testing of FCUs as per UL1995 Standard at the HACE factory, Riyadh on dated Feb

ENERGY ENGINEERING INTERNATIONAL FACILITIES SERVICES L.L.CI2, 17th FLOOR, INTERNATIONAL BUSINESS CENTER, BLDG 27 WEST 10, THREE SAILS TOWER

P.O BOX 42284, ABU DHABI, UNITED ARAB EMIRATES. PHONE:+971-2 6815555, Fax: +971-2 6817744 www.energyengg.com

mailto:[email protected]

mailto:[email protected]

ENERGY ENGINEERING INERNATIONAL FACILITIES SERVICES L.L.C

INSPECTION REPORTReport No: IR04 Revision: 00 Date: 05-02-2015 Page : 1 of 15

03rd 2015. This inspection was scheduled to complete the remaining test which were not done on Jan 27th 2015 and mentioned in Inspection report# 03.On the same units the remaining test were performed which were used during the test on Jan 27th 2015. Three FCU units of different models were available at the HACE factory which has been sent from Contractor site to Manufacturer for Testing.

ATTACHMENTS HOURS

1 Fan Control Units Equipment Schedule TOTAL VISITS /

HOURS TILL DATEVisits / Hrs2 Email From Level sensor manufacturer for the suitable

with water.

3 Motor data sheets, drain pump data sheet and level sensor data sheets provided by Manufacturer. TOTAL HOURS

DURING THIS VISIT

INSPECTION TRAVEL REPORT TOTAL

4 HACE internal Calibration tracking records

5

Non Conformance Outstanding

Yes No NCR. No.

Prepared by: Zubair Ahmad Approved by:

Date: Feb 03rd 2015 Date:

1. ATTENDEES

NAME COMPANY REPRESENTED TITLE

Zubair Ahmad Energy Engineering TPI

Abdullah Hafeez HACE QC Manager

Edmundo Gabriel HACE R & D Engineer

Mohammad Gulzar HACE QC Inspector

2. SCOPE OF VISIT

Scope of the visit was to witness the Testing of FCUs as per UL1995 Standard on 03-02-2015 at HACE.

3. VISIT SUMMARY



It was an inspection notification for Testing of FCUs as per UL1995 Standard at the HACE factory, Riyadh on Feb 03rd 2015. This inspection was scheduled to complete the remaining test which were not done on Jan 27th 2015 and mentioned in Inspection report# 03.On the same units the remaining test were performed which were used during the

test on Jan 27th 2015. Three FCU units of different models were available at the HACE factory which has been sent from Contractor site to Manufacturer for Testing. The FCU units which has been sent for testing which model number are mentioned below:

FCU Model number Tag number and Serial Number Quantity

DAV-030 BOH-K-FCU-011-RH and F/229/14 01

CB1-10 A-K-FCU-502-RH and F/238/14 01

GCH-600 FCU-01-01-RH and F/240/14 01

4. INSPECTION DETAILS ( Refer ITP If applicable)

5.1 Monitoring

Not Applicable

5.2 Visual Inspection

Not Applicable

5.3 Dimensional Inspection

Not Applicable

5.4 Testing (if any)

Three FCU units of different models were available at the HACE factory which has been sent from Contractor site to Manufacturer for Testing. The FCU units which has been sent for testing which model number are mentioned below:

FCU Model number Tag number and Serial Number Quantity

DAV-030 BOH-K-FCU-011-RH and F/229/14 01

CB1-10 A-K-FCU-502-RH and F/238/14 01

GCH-600 FCU-01-01-RH and F/240/14 01

For the above mentioned units, testing has been done as per the UL-1995, table-38.2, column 1 (units without supplementary heat) as applicable to the FCU units.

The Dielectric voltage withstand test was already done on dated Jan 27th 2015. Satisfactorily, Regarding the rain test the UL email is already sent to the Contractor/ client for their acceptance. The details of these tests are already mentioned in inspection report#03.

The reaming test has been done as per the UL-199, table-38.2, column 1 ( units without supplementary heat) as applicable to the FCU units and details are mentioned below:

1. Condensate Drain Blockage Test :



1. EMPLOYED DOCUMENTS

DOCUMENT NO. REVISION TITLEAPPROVAL

STATUS

Ul-1995 1999 HEATING AND COOLING EQUIPMENT NA

Regarding the drain blockage test, manufacturer informed that this test is not applicable because in all units drain pan is located below the all electrical parts. As per UL-1995, clause 53.2, if the drain pan is located below all electrical parts, Condensate drain blockage test may be Waived. As the word “May be “is used. Client has to provide the conformation that either this test is required or not.

To verify that Drain pan is located below the all electrical parts, the Manufacturer was asked to provide the documents to verify installation direction/ mounting of these units. Manufacturer has provided one, “Fan Control Unit Equipment Schedule” (For reference it is attached with the report). Confirmation from Contractor is required for the attached “Fan control Equipment Schedule”.

Condensate drain block test for GCH-600 :

For GCH-600 unit, the drain pan is provided just above the all motors, fan and electrical circuit. The test was done for GCH-600. During overflow of drain pan it was observed that water was coming to the enclosure, retained in closure and the electric circuit wiring was dipped in the retained water. Moreover there was a chance that the wiring terminal blocks will be dipped in the retained water in enclosure if the water overflow will be for long time and also water can come on the transformer which is installed under the drain pan. But as per UL1995, clause 53.1, during the drain lockage test water shall not retain within enclosure for electrical parts and wiring.

To assure the motor winding, after the drain blockage test, as required by UL1995, clause 53.1, the Dielectric Voltage withstand test was done and found acceptable.

Condensate drain block test for DAV-030 :

For the DAV-030, the drain pan was found below the all electrical parts. As per UL-1995, clause 53.2, if the drain pan is located below all electrical parts, Condensate drain blockage test may be Waived. As the word “May be “is used. Client has to provide the conformation that either this test is required or not.

Condensate drain block test for CB1-10 :

For the CB1-10, in the installed position as the discharge of the unit is horizontal position the drain pan was found below the all electrical parts. As per UL-1995, clause 53.2, if the drain pan is located below all electrical parts, Condensate drain blockage test may be Waived. As the word “May be “is used. Client has to provide the conformation that either this test is required or not.

Moreover as per provided “Fan Control Equipment Schedule”. For model CB1- 10, it is mentioned the installation as “Celling Concealed Duct Unit” So, from this installation statement it was not clear that what will be the discharge air direction either Vertical up or below or Horizontal. Manufacturer informed that this unit will be installed in the position with the discharge opening horizontal. Confirmation from Contractor is required on it.

2. Loading Test :

Loading test was done for all three units as per UL-1995, clause 54.

Loading Test for DAV-030 :

For DAV-030, the loading test was done in the instated position as per provided “Fan Control Equipment schedule”. The load is applied as per the requirement of UL1995, clause 54 and found acceptable.

Loading Test for GCH-600 :

For Loading test, as per UL 1995, clause 54.1, a substantially horizontal plane on the top of equipment shall be capable of sustaining a static load applied in vertical position. But for GCH-600, when the unit is installed as per the provided “ Fan control equipment Schedule”, the top was the discharge air opening and there was not horizontal plane at the top to do the load test as required by the UL-1995, clause 54.1. The top pane was inclined



with fan guard. So, Load test was done in the position 90 degree moved (the discharge opening in horizontal position) from the actual installed position and results were found acceptable. As the test is done in the different position of unit from actual, the acceptance from client is required on it.

Loading Test for CB1-10 :

For CB1-10, load test was done in the position when the discharge opening is in Horizontal position. During the loading test of the CB1-10, it was found that when load is applied on the top the top surface was deflected and was touching with the Case of the fan which is moving equipment. But as per UL1995, clause 54.1, the load shall not result in a deflection that causes the structure to contact a moving part.


3. Temperature Operation Test and Input Test :

Temperature Operation Test :

For all three units, the Temperature operation test was done as per UL1995, clause 40. The temperature of all the applicable devices/ equipment/ wiring surfaces/ transformers/ capacitors/ surfaces etc was checked as per table 38.5 and fond acceptable.

The observations of the test setup are mentioned in below input test section.

Input Test :

For all three units the Input test was done as per UL1995, clause 39.1. All the input parameters were checked as required i.e. Voltage, Current ( FLA), Fan RPM etc and results were found acceptable except as observation mentioned below:

(i) During input test the fan RPM were measured and found different from specified in motor data sheet as mentioned below:

FCU Model number Required RPM as per data sheet Actual Found RPM

DAV-030 880 1154

CB1-10 1200 1285

GCH-600 1200 Fan1: 1459, Fan 2: 1451

HACE to respond on it.

(ii) For DAV-030 and CB1-10, for input test, the setup was done without inlet duct and the static pressure was maintained by putting the one sensor side of instrument at discharge duct and second side in open atmosphere. But as per UL1995, clause 381.4, the for units utilizing the inlet duct the other side of instrument shall be connected to inlet duct. This matter was discussed with HACE (manufacturer). Manufacturer informed that for them these units are without inlet duct and they also do not that at site if the inlet duct will be used for these units or not and if used what will be the layout of inlet duct. So, For TPI Contractor has to discussed and resolve the matter and acceptance from Client is required on it.

(iii) For Unit GCH-600, input test and Temperature operation test was done without any inlet and out let duct (No static pressure was maintained between inlet and outlet duct). Both inlet and out let were on same atmospheric pressure. This matter was discussed with manufacturer. Manufacturer informed that this GCH-600 will not be installed at any inlet and outlet duct and both inlet and outlet will be at same atmospheric pressure. Acceptance from client is required on manufacturer statement.



(iv) For input and Temperature test, the unit CB1-10 was set up in the position with the discharge in horizontal position. As per provided “Fan Control Equipment Schedule”. For model CB1- 10, it is mentioned the installation as “Celling Concealed Duct Unit” So, from this installation statement it was not clear that what will be the discharge air direction either Vertical up or below or Horizontal. Manufacturer informed that this unit will be installed in the position with the discharge opening horizontal. Confirmation from Contractor is required on it.

4. General :

(I) A difference was found in the Air Flow mentioned in the unit data sheet and “Fan control equipment schedule”. However during test the requirements for both were meeting.

(II) For units GCH-600 and DAV-030, on the actual motor name plate, the wattage rating was not mentioned. However the wattage rating was verified with the motor data sheets provided by manufacturer because the model number mentioned on the actual motor name plate was same as mentioned on the motor data sheet (which also includes the motor wattage rating).

(III) The Temperature sensors which are used to measure the temperature it is not traceable that these are thermocouple or RTD. Manufacturer informed that these are Thermocouple. Written confirmation from Manufacturer is required on it as it is a requirement of UL1995.

(IV) Manufacturer to provide the test report for all three units test and it will be signed by TPI after the close out of all comments/ observations.

5.5 NDT

Not Applicable

5.6 Painting/Coating

Not Applicable

5.7 Packing / Shipment

Not Applicable

5.8 Equipment used :

The below mentioned equipment are used during test. For all equipment except the Hi pot test and Anemometer, manufacturer has provided their internal calibration tracking record which is not the proper calibration certificate. Manufacturer to provide the Proper calibration certificate for all equipment. Moreover for thermocouple (03 nos) no calibration certificate was available. For reference the internal calibration tracking record is attached.

Equipment Sr. No/ ID Equipment Description Calibration Due Date

-- HI Pot Tetser Oct 19th 2015

GW001 Weighing Balance 25-04-2015

0200293 Clamp Meter 22-03-2015

G7031 Digital Thermometer 06-02-2015

10150113 Anemometer 14-05-2015

S338848 Tachometer 11-02-2015

G8008 Digital Manometer 25-07-2015



5075 Air Flow meter 06-02-2015

-- Thermocouple ( 03nos) --

5. EXPEDITION DETAILS

7.1 ENGINEERING:

Not Applicable

7.2 PROCUREMENT:

Not Applicable

7.3 PLANNING:

Not Applicable

7.4 FABRICATION:

Not Applicable

7.5 MDR & INSPECTION STATUS:

Refer the Section “INSPECTION SAMMARY AND CONCLUSION:”

6. DOCUMENTS/REPORTS REVIEWED

None

7. OBSERVATIONS / CONCERNS IF ANY

Observation raised during this inspection 03-02-2015:

1. For GCH-600 unit, the drain pan is provided just above the all motors, fan and electrical circuit. The test was done for GCH-600. During overflow of drain pan it was observed that water was coming to the enclosure, retained in closure and the electric circuit wiring was dipped in the retained water. Moreover there was a chance that the wiring terminal blocks will be dipped in the retained water in enclosure if the water overflow will be for long time and also water can come on the transformer which is installed under the drain pan. But as per UL1995, clause 53.1, during the drain lockage test water shall not retain within enclosure for electrical parts and wiring.

2. For the DAV-030, the drain pan was found below the all electrical parts. As per UL-1995, clause 53.2, if the drain pan is located below all electrical parts, Condensate drain blockage test may be waived. As the word “May be “is used. Client has to provide the conformation that either this test is required or not.

3. For the CB1-10, in the installed position as the discharge of the unit is horizontal position the drain pan was found below the all electrical parts. As per UL-1995, clause 53.2, if the drain pan is located below all electrical parts, Condensate drain blockage test may be waived. As the word “May be “is used. Client has to provide the conformation that either this test is required or not.




4. For loading test, as per UL 1995, clause 54.1, a substantially horizontal plane on the top of equipment shall be

capable of sustaining a static load applied in vertical position. But for GCH-600, when the unit is installed as per the provided “ Fan control equipment Schedule”, the top was the discharge air opening and there was not horizontal plane at the top to do the load test as required by the UL-1995, clause 54.1. The top pane was inclined with fan guard. So, Load test was done in the position 90 degree moved (the discharge opening in horizontal position) from the actual installed position and results were found satisfactory. As the test is done in the different position of unit from actual, the acceptance from client is required on it.

5. For CB1-10, load test was done in the position when the discharge opening is in Horizontal position. During the loading test of the CB1-10, it was found that when load is applied on the top the top surface was deflected and was touching with the Case of the fan which is moving equipment. But as per UL1995, clause 54.1, the load shall not result in a deflection that causes the structure to contact a moving part.


6. During input test and Temperature measurement test following observations are made a mentioned below:

(i) During input test the fan RPM were measured and found different from specified in motor data sheet as mentioned below:

FCU Model number Required RPM as per data sheet Actual Found RPM

DAV-030 880 1154

CB1-10 1200 1285

GCH-600 1200 Fan1: 1459, Fan 2: 1451

(ii) For DAV-030 and CB1-10, for input test, the setup was done without inlet duct and the static pressure was maintained by putting the one sensor side of instrument at discharge duct and second side in open atmosphere. But as per UL1995, clause 381.4, the for units utilizing the an inlet duct the other side of instrument shall be connected to inlet duct. This matter was discussed with HACE (manufacturer). Manufacturer informed that for them these units are without inlet duct and they also do not that at site if the inlet duct will be used for these units or not and if used what will be the layout of inlet duct. So, For TPI Contractor has to discuss and resolves the matter and acceptance from Client is required on it.

(iii) For Unit GCH-600, input test and Temperature operation test was done without any inlet and out let duct (No static pressure was maintained between inlet and outlet duct). Both inlet and out let were on same atmospheric pressure. This matter was discussed with manufacturer. Manufacturer informed that this GCH-600 will not be installed at any inlet and outlet duct and both inlet and outlet will be at same atmospheric pressure. Acceptance from client is required on manufacturer statement.

(iv) For input and Temperature test, the unit CB1-10 was set up in the position with the discharge in horizontal position. As per provided “Fan Control Equipment Schedule”. For model CB1- 10, it is mentioned the installation as “Celling Concealed Duct Unit” So, from this installation statement it was not clear that what will be the discharge air direction either Vertical up or below or Horizontal. Manufacturer informed that this unit will be installed in the position with the discharge opening horizontal. Confirmation from Contractor is required on it.

7. The equipment mentioned in section 5.8 of this report are used during test. For all equipment except the Hi pot



test and Anemometer, manufacturer has provided their internal calibration tracking record which is not the proper calibration certificate. Moreover for thermocouple (03 nos) no calibration certificate was available. Manufacturer to provide the Proper calibration certificate for all equipment. For reference the internal calibration tracking record is attached.

8. The temperature sensors which are used to measure the temperature it is not traceable that these are thermocouple or RTD. Manufacturer informed that these are Thermocouple. Written confirmation from Manufacturer is required on it as it is a requirement of UL1995

9. Manufacturer to provide the test report for all three units test and it will be signed by TPI after the close out of all comments/ observations.

Status of observation raised during the last visit; 27-01-2015:

HACE to provide the Calibration certificate of the HI Pot Tester for review/ verification.

Status: Calibration certificate is provided and found satisfactory. Closed.

Rain Test :

Regarding the Ran test HACE informed that this test is not applicable for these units because these are for indoor used. In UL-1995, it is not mentioned anywhere that rain test is not applicable for indoor units. Regarding this manufacturer provided on email from UL “Underwriters Laboratories” which states that “NO NEED OF RAIN TEST FOR INDOOR INSTALLATION”. For reference, Email from UL is attached. Acceptance on this Email is also required from Client Moreover It was not clear that these units are indoor or outdoor. So, confirmation from Contractor is required that these units are for indoor.

Status: Open

Condensate Drain Blockage Test :

Regarding the drain blockage test manufacturer informed that this test is not applicable because in all units drain pan is located below the all-electrical parts. As per UL-1995, clause 53.2, if the drain pan is located below all electrical parts, Condensate drain blockage test may be waived. As the word “May be “is used. Client has to provide the conformation that either this test is required or not.

Status: Open

Moreover, to verify that Drain pan is located below the all-electrical parts, the Manufacturer was asked to provide the documents to verify installation direction/ mounting of these units. Manufacturer has provided one, “Fan Control Unit Equipment Schedule” (For reference it is attached with the report). Confirmation from Contractor is required for the attached “Fan control Equipment Schedule”.

Status: Open

As per the provided, “Fan control Equipment Schedule”, the drain pan location was checked to verify that either this test is required or not and following observation has been made.

I. As per provided “Fan Control Equipment Schedule”. For model GCH -600, it indicated that it is floor mounted. If it is floor mounted then the drain pan is located above the Motors, fans and all control panel circuit. So, the Condensate drain blockage test is required as per UL 1995, clause 53. HACE to respond.

Status: For this unit the test was done. The observations are made. Refer the “Comments raised on dated Feb 03rd 2015. Open.

II. As per provided “Fan Control Equipment Schedule”. For model CB1- 10, it is mentioned the installation



as “Celling Concealed Duct Unit” So, from this installation statement it was not clear that what will be the discharge air direction either Vertical up or below or Horizontal. This information is required to know that either Condensate drain block test is required or not because after correct installation position it will be known that were is the location of the drain pan. HACE/ Contractor to respond on it.

Status: Open.

III. For all three units, drain pump is use which is directly located on the drain pan. It is observed that a level sensor is provided which will be always dipped in the water of drain pan. This matter was discussed with manufacturer. Manufacturer informed that this sensor is sealed type and there will be no hazard due to this level sensor as it is manufacturer for this purpose. So, HACE has to provide the Guarantee certificate from the level sensor manufacturer regarding this.

Status : Regarding this comment, a guarantee certificate from the level sensor manufacturer is required but only the email from sensor manufacturer is provided which states that “ it is water proof” For reference email is attached. This point was discussed with HACE and they informed that they are in contact with sensor manufacturer and guarantee certificate will also be provided. So, HACE to provide the Guarantee certificate. (Open)

Input Test, Temperature Operation Test and Loading Testing : ( Not Done)

Input Test, Temperature Operation Test and Loading Testing were not performed due to the time limitation and the time was required to arrangement/ setup of the units as required by UL-1995, clause 38. It is informed to the manufacturer as do all the arrangement as required by the UL-1995 respective clause for required test. Manufacturer informed they will make arrangement to do remaining tests.

Status: This was for information only.

8. ATTACHMENTS

Fan Control Units Equipment Schedule, Email From Level sensor manufacturer for the suitable with water. Motor data sheets, drain pump data sheet and level sensor data sheets provided by Manufacturer & HACE internal Calibration tracking records.

Photos



Condensate drain block test

Loading Test for DAV-030



Loading Test for GCH-600

Loading Test for CB1-10





Temperature Operation Test and Input Test

---------------------------------------------------END OF REPOR T-------------------------------------------------------------



Documents

IR#04 010320140100 HACE 03-02-2015.doc