SOD-08556 - LSP-005 -FAT-005

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


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


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


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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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


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


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


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


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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2.6 Gas distribution system


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


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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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



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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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2.8 ECU-2 (ECU-C-101-011) ECU Testing shall include the following.

2.8-1 QC Checks


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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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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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




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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


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


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.


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


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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4. Control Measures The following are typical controls which may be required from the task risk assessment


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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