Quality Plan

MANUFACTURE QUALITY PLANProduction Flow Diagram

With referenced to Clients project specific requirement and related Standard applied . All design & drawing & material submitted to client for review & approval , Any correction made re-submit for approval by client.

Production , FAT & SAT will all be based on this approval.

Hvac production calculation base on ARI , ASHRAE , SMACNA and NEC standard.Design & drawing included but not limited to :

1. General layout

2. Data sheet

3. Specification4. Block diagram

5. P&ID diagram

6. Hvac Design calculation

7. Fresh air transit Vs Gas damper closing calculation

8. Load calculation

9. Cable schedule

10. Hvac design drawing

11. Electrical diagram

12. Control Panel drawing

13. PLC Ladder logic development & Listing

14. Utility consumption / Load list

15. Grounding system planning

16. Material take off

17. Inspection Test Plan

18. Factory acceptance procedure

19. Operation manual book

Material involved in the project purchaced through local authorized agent if any , or direct imported from manufacturer.

All material strictly comply to type number / catalog number / specification as said in the approval document, and brand new.

A copy of un-priced order may be available for client reference only.

Depend , some material duty may be payed by Client or included in the contract.

All material and/or component received accompany with a Certificate ( COO /Conformance/Manufacture certificate/ third party certification such FM / UL / Marine etc ).Material include :

Fins ( aluminium / copper / stainless steel & Tube )

Metal sheet ( SS316L , Mild sheet steel / others )

Compressor , Motor , Blower , Fan , Gas damper , Dampers etc

Cables , Lug

Electrical components ( breaker , magnetic contactor , relay etc )

Insulation material

Coating material

Box

ETC

Quality check apply for packaging condition , appearance. Although rare , Cracks / moisture / dirt found may be subjected to rejection for particular material , and report is made and documented.

Material received checked for Type no / Part no / Specs , of which must be exactly the same as stated in Purchase Order. Any deviation will be rejected. We apply zero tolerance for material quality impair.Substitue is not allowed.

Certificate & manual are documented.

Once the material is received , production may be started.Production :

1. Sheet metal ( cutting , forming , CNC punching ) for housing of AHU , Condensing and Pressurizing unit and Ducting.2. Metal sheet welding for structure & ducting.

3. Coils fabrication

QC :

1. Leak Test for Coils produced. ( 400 Psig for 60 minutes & water tank submerged ).

2. Metal sheet surface finishing after welding.

Assembly guideline :

1. Follow color codes.

2. Follow cable ampacity rating.

3. Follow cable lug sizing code.

4. Follow hazardous classification requirements and material.

5. Maximum 2 cable lug in one terminal block.

6. Every equipment must be hard grounded.Assembly :

1. Assembly of all component ( compressor , Fan , blower , motor etc ) to form a complete Hvac unit.

2. Refrigerant pipe welding work.

3. Electrical wiring & laying.

QC :

1. Leak test for refrigerant piping after spool forming/welding.

2. Continuity & Insulation test with 500V tester.

Electronic measuring instrument used :

Clamp ampere meter ( RMS )

AVO meter ( RMS )

Insulation tester 500/1000 V

Air flow meter

Thermometer ( dry & wet bulb )

Digital thermometer

Non contact infra red thermometer

Noise meter

RH humidity meter

Computerized temperature data logger ( Cooling capacity measurement )

Vibration meter

After assembly , internal test run for individual component and Hvac system check.

Test data is recorded in the following form.

HVAC TEST RECORD

NODESCRIPTIONAHU A

TAG NO.FP-HVAC-000AAHU B

TAG NO. FP-HVAC-000B

1Test Start time:

Date

Run Time ( Minute )

2Record Time :

Start record

Stop record

3Electrical consumption ( Ampere )

Compressor ( A )

Motor Fan #1 ( A )

Motor Blower ( A )

Press Fan motor ( A )

4Refrigerant side

Suction Pressure (Psig)

Discharge Pressure (Psig)

5Air Side Condenser

Face Area Fan ( m2 )

Velocity ( m/s )

Ambient Temp ( o CDB )

Output Air Temp ( o CDB )

T Condenser ( o C )

6Noise level ( dB ) 3 m from unit

7Air side Evaporator

Face area blower (m2 )

Velocity blower ( m/s )

Fresh air intake

Output Air

A = Ampere / Phase at 460Vac 60 Hz

Psig = Pressure per Square Inch gage

M2 = Square meter

m/s = Meter per second

o C = Centigrade Celcius

o CDB = Celcius dry bulb

o CWB = Celcius wet bulb

T Condenser ( o C ) = Output Ait Temp ( o CDB ) Ambient Air Temp ( o CDB )

Record is compare to equipment data sheet. Normally capacity used maximum not exceeding 80% of maximum equipment rated load.

Output data / air flow / temp / pressure must meet design parameter criteria. Any anomalies

is corrected / adjusted.

Hvac capacity recorded with the following ASHRAE Chart as :

PH Enthalpy diagram

COP

Insulation test Records

HVAC COIL RESISTANCE & INSULATION TEST RECORD

NODESCRIPTIONCOMPRESSORMOTOR

BLOWERMOTOR

FAN MOTOR

PRESS FAN

1Winding resistance test

AVO Meter

T1-T2 ( ohm )

T1-T3 ( ohm )

T2-T3 ( ohm )

2Insulation test

MEGGER 500 Volt

T1 GND ( M Ohm )

T2 GND ( M Ohm )

T3 GND ( M Ohm )

Note:

Preparation for Factory Acceptance Test or FAT based on the project document above.Records and Measurement are prepared for FAT.

High visible tapes is mounted to mark the FAT boundary area.

FAT test is intended to proof that the finish factory product has meet or exceed the design requirement.Test may be include :

Dimensional check

Functional check

Air flow

Temperature ouput

Humidity

Pressure

Cooling capacity & COP Response of gas damper

Backup scheme

Alarm handling

Alarm logging & print out

Interface operability with other system

Leak test

Certification by third party certification institution available upon request by contract.

Such as:

- Sucofindo

- BKI ( Biro Klasifikasi Indonesia )

- Surveyor Indonesia

A packing list contain information on : Client name

Project no Content

Name of equipment

Bill of material

Certificate of lifting & NDT report on welded steel ( if any )

Weight

MSDS ( Material safety data sheet ) if contain liquid or gas substance

All pipes and cables must be end-cap for water proofing.

Equipment must be whole plastic wrapping.

All openings / flanges / joints must be secured for water proofing.All Ducting must be plastic wrapping for water proofing.

Ensure all equipment contain is secured and bolted to packing bottom and not moving during transportation , lifting.

Our site engineer is available for installation or supervision , to ensure that all engineering aspect is meet. This include mobilisation on-site , un-packing , installation , testing and commissioning.

Training for operation & maintenance staff for Client to ensure the System is understood and easyly and safely operated and maintained beyond installation.

Whether it is electro-mechanical or PLC based system , instruction is clearly written and explain to operation staff.A operation manual of the system is provided.

All documents included technical manual ( softcopy and print out ) is provided.Notes :DRAWING & DESIGN APPROVAL BY CLIENT

MATERIAL PURCHASE

MATERIAL RECEIVING & DOCUMENTED

PRODUCTION & ASSEMBLY

QUALITY CONTROL

SITE INSTALLATION ASSISTANCE

DOCUMENT PREPARATION FOR

FAT & DELIVERY

FACTORY ACCEPTANCE TEST

& CERTIFICATION

PACKING & DELIVERY

FACTORY INTERNAL TEST RUN

& AS BUILT DOCUMENTATION

DRAWING & DESIGN APPROVAL BY CLIENT

MATERIAL PURCHASE

MATERIAL RECEIVING & DOCUMENTED

PRODUCTION & ASSEMBLY

FACTORY INTERNAL TEST RUN

& AS BUILT DOCUMENTATION

DOCUMENT PREPARATION FOR

FAT & DELIVERY

FACTORY ACCEPTANCE TEST

& CERTIFICATION

PACKING & DELIVERY

SITE INSTALLATION ASSISTANCE

& TRAINING and DOCUMENTATION

MANUFACTURE QUALITY PLAN

Rev 1.2013