CREATE,located at NUS University Town, Singapore project was completed in mid year 2011.
PowerQ was involved in this project from late year 2010 to mid 2011 and our scope comprised of base build system and equipments serving the research facilities. We had tested and commissioned more than 200 mechanical equipment which are controlled and monitored by Central System.
The T&C was performed under the general supervision and direction of the M&E Contractor and Consultants. For the post greenfield project during year 2012, PowerQ had commissioned several BSL labs including reliability test for various system such as CDA, Gasses, Vacuum, Electrical, Fire, BMS, DCP CHW and ACMV.
Park Hyatt Ningbo, a 200+ rooms' resort and villas is located on the slopes of the banks of Dong Qian Lake in Ningbo, China. http://www.ningbo.park.hyatt.com has started its operation since the end of year 2011.
PowerQ provided Third Party Commissioning consultancy service to the project developer MTL for entire MEP and utilities systems comprising of HV Electrical system, Emergency Generator System, Boilers, Hot Water System, HVAC System, Fire Protection, Alarm system, Integrated Building Automation and Security system. PowerQ had performed Verification and Function Performance and Integration Test of the systems and issued a Commissioning report comprising of Building Authority certificates, test records and recommendations for future operations and maintenance.
PowerQ Engineers were stationed at site for a period of one year and assisted owner's MTL team to identify potential issues, advise changes to optimise performance. We verified systems operation by performing systematic testing and commissioning to meet the demanding needs from Hyatt.
In year 2012 , PowerQ had performed Harmonics study for the largest heavy lift and pipe laying vessel. The entire power system was modelled using SKM software and harmonics were predicted and compared to class limit .
The results of simulations were validated on site by conducting an actual simulation. This was done by operating loads such as 3000T main crane, Propulsion Thrusters, Tunnel Thrusters, Winches and Tensioner. Site testing was carried out using high specs Power Quality recorder-FL434.
Post site simulation using the software model was updated based on site data. Software study was re-run. Accordingly, various recommendations were made to mitigate harmonics issues .
In year 2011, PowerQ received a call from a long-term client for an urgent site inspection. The client reported that the condenser's 3 out of 5 pumps failed. They were concerned about these failures as it will significantly hamper the total tonnage of the cooling plant.
In response to this event, the client requested PowerQ to conduct inspections to determine the possible cause of this failure and to recommend further actions. PowerQ inspected the failed impellers and found the causes.
There were holes and minor cracks in the impeller. In accordance to that, PowerQ's Mechanical Engineers surveyed the systems including the pipings, cooling towers, strainers, water quality, chemical treatment dosage etc. PowerQ had performed measurements. Finally, equipped with various data, a Root Cause Analysis (RCA) was performed .
The root cause was found to be a localised failure due to water contamination along with mud and sediment debris. This could be the reason the impeller had eroded.
Recommendations were made that is to install an automatic sand filter with regular blow down and an automatic dosing system. Finally, the impellers were replaced, the shaft aligned and balanced. After this rectification, there were no other failures reported.
In 2013-2014, PowerQ performed commissioning for civil defence shelters Mechanical, Electrical, Control and Fire Protection. The shelter is designed to protect mission critical electronic system to withstand NBC Hazard, shockwave cased by blast forces, forces of projectile, extreme heat and fire. It has to maintain functional when encountered with these situations.
The shelter was designed for +15g forces. It was required that the substructures, equipments and instruments have to survive mechanical shocks. To meet this challenge, PowerQ team worked with civil and structural, mechanical and electrical teams in an integrated approach. The shelter is designed to be fully functional without relying from external utilities for a prolong period of several days.
Once the structure was substantially completed by civil and structural contractor, PowerQ inspected it and the components such as the blast door and overpressure blast valves. The contractor’s team had painstakingly ensured that all the leaks including hairline cracks were sealed. At the next stage, PowerQ Engineers set up test equipments and data loggers to conduct Air Tightness and IOPT Test at +250pa. The pressure was held for a specified duration until it was confirmed that the leakage rate is lower than allowable 8%. Once the structure was declared gas tight, the services installation commenced.
This test was followed by the review of system drawings and the preparation of method statement for Overpressure Regime Test (ORAT). Test was conducted by pressuring the structure with the use of installed fans.
After successful completion of ORAT, the individual functional test were carried out for Electrical System, Prime rated Standby Generator, UPS, Door Monitoring Security System, Fire Alarm/VESDA/Co2, Fire Sprinkler System, Plumbing and ACMV system.
Finally, an Integration test and scenario test were conducted for the entire shelter. It was performed in a Peacetime/Normal, conventional, filtration and button up (closing FA intake) scenario and various performance parameters such as flow rate, power generation/consumption, sound level, lux level, temperature/RH and room pressures. PowerQ supplied Engineers, test equipments and data loggers to perform final Acceptance Test for Govt authorities and submitted a final analysis report.
Throughout the years, PowerQ have gained experiences in conducting similar services for mission Critical Facilities such as; Underground Metro Station, Isolation Suits and Operation Theatres in hospitals, Blast proof rooms in oil rigs, FM200/C02, Pressurised Room in data centres, BSL negative pressurised rooms in animal holding facilities/Vivariums and BSL labs.
In year 2013, one of our clients who had been incurring an extremely high utilities bill for a period of time, approached PowerQ to review their billing.
The Biosafety Level 3 Lab was a research facility with more than 24 ACH. Based on the design, air was not reticulated to protect the scientists safe from any hazards such as chemicals, virus and bacteria.
PowerQ reviewed the billing in comparison with other similar facilities and had proposed to:
The challenge was to save energy while not interrupting lab operations and the hardware or control systems.
PowerQ performed the following tasks:
Task A – Brief Review Of Specification and Construction As-Built Drawing
PowerQ reviewed the following specifications for mechanical and electrical systems. These include:
Task B - Site Verification of Performance Operation
Performance evaluation of energy systems such as environmental control laboratory. This is to determine the actual performance of the current running unit against the design value. Air volume measurement and pressure profiling in comparison with the design were done. Spot reading of selective AHU, operating current, air flow static pressures and supply/return temperature, review of current BMS data, operational data and operating hours of fume hood and lab system were evaluated.
Task C – Implementation of Energy Saving Measures
The Following were implemented to reduce energy consumption:
After implementation of the energy saving measures, the energy bills were monitored for 6 months. It was established that more than 20% reduction in energy billing was achieved.
In year 2013, PowerQ performed validation of custody transfer gas metering system for a 6mpta LNG terminal. This is an onshore LNG import/export terminal comprising of facilities for LNG unloading/reloading, LNG storage, Boil-off Gas (BOG) Handling, LNG send-out, LNG re-gasification and natural gas metering and regulation.
LNG is imported from LNG tanker, offloaded through unloading arm and pumped at LP to storage of half million cubic meter capacity. From storage tanks, the LNG was pumped at HP to bulk consumers at pressure in excess of 500 psi.
The export system is equipped with specialized Gas Metering Systems that support the Gas metering and Gas Quality Monitoring. The metering stream configuration for each metering skid is configured with pay and check meters of 2 x 100% (i.e. one active and one standby).
This validation plan addresses the following sub-systems of the Gas metering system:
PowerQ performed validation exercises in four phases as follows:
The validation was performed under the available gas flow rate (approximately 60K cu.m/hr) and the condition of the gas. It was noted that the gas flow rate was within the design range but was not the expected design flow rate.
The gas metering system was validated based on hourly flow rate accuracy of ±1% as per specification and as per gas code. However, the metering accuracy varies according to flow rate.
PowerQ final analysis report recommended that calibration program of periodic calibration of critical instruments shall be implemented according to an approved schedule and approved calibration procedures. It is recommended for periodic test and calibration of meter installations as guided by codes.
In conclusion, the design, installation, operational and performance validation conducted by PowerQ validated that the pay and check metering system performed with reasonable accuracy. It is within tolerance limit of the overall inaccuracy of the system, and is acceptable and eligible for custody transfer.
A bus depot to house about 500 buses was topped up in the third quarter of 2015. The depot located in Jurong is equipped with facilities for bus repair and maintenance, daily bus operations, and administrative area. PowerQ was engaged by D&B contractor, to oversee installation on quality of various specialised systems incorporating the latest technology in its equipment and was designed to increase efficiency in the client’s operations.
PowerQ provide inspection and T&C supervision services for the following:
During construction period, PowerQ Engineers witnessed all construction tests such as welding NDT test, pipe pressure test, megger, tank leaks test and gas leak test.
Once construction is completed, the site acceptance method statement, safety and assurance documents were reviewed before SAT with authorities. Individual systems were tested and commissioned for functional performance before calling for SAT.
The challenge was to conduct SAT for various systems simultaneously in short duration in a week. The D&B contractors prepared a comprehensive schedule and monitored SAT was mentored closely.
The completed system was handed over to operator in the third quarter of 2015.
Other Similar Projects:
Previously, PowerQ had helped in Auditing and Troubleshooting of mould and humidity at an Aircraft hangar at Seletar.
In the first and second quarter of year 2015, PowerQ had performed commissioning for HVAC, Mechanical and related Electrical and Control system, for JDP. This ship is fitted to work in sub-zero to +45 Deg Celsius ambient. The 100M+ long multi-purpose offshore construction vessel ship can accommodate more than 400 crew members working round the clock to lay sub seas piping. Being a DP ship utilities such sea water, electricity were supplied by separate sources located in starboard and port side.
The scope comprised of balancing, equipment performance test, commissioning, integration and site acceptance test for chillers, seawater pumps, humidifiers, AHU, SCR Electrical heaters, cold rooms and related Electrical and PLC based control system. Challenge was to simulate performance test for sub zero and < 20% RH weather condition. This was achieved by artificially resetting set points in control system to trigger functions of equipments such as humidifiers, air heater, dampers and valves. After successful completion of SAT test, the performance was again validated by Client in a week long sea trials.
Various conditions were simulated with assistance of experienced contractor FW, to commissioning the mechanical, HVAC and related PLC based control and electrical system.
Other Similar Experiences:
In year 2011, PowerQ performed electrical system audit and performance test (using artificial loads) in South China Sea for a similar ship with crane of 3000T capacity.
PowerQ had provided testing and commissioning services for an air-cooled Sports Complex where the client was concerned that any leak from internal insulation to concrete wall will result in energy loss. PowerQ was engaged to conduct thermal imaging on 8 units of tanks with height of more than 8m. Client had commissioned PowerQ to carry out external thermal imaging by identifying any temperature gradient on concrete surface indicating leak.
PowerQ had conducted baseline thermograph measurement of the Thermal Storage tanks and identification of any temperature anomaly on concrete tank using an industrial-grade thermal imaging camera. A thermal image of a tank that’s completely empty or completely full, or which has a shiny reflective skin will appear uniform and no product level will be apparent. Otherwise, the product level will appear as an evident thermal separation between the headspace and chilled water.
Thermography results reveals the interface between the liquid and the gas (usually air) in a tank, indicating its full capacity and whether break in thermal insulation were found and identified subsequently for further rectification.
Additionally, PowerQ performed calculations for every pump head, and conducted pump performance test for charging pumps to determine adequacy of head.