DESIGN, SUPPLY, INSTALL, TESTING AND COMMISSIONING WORKS FOR:

PHASE 1 – COOLING TOWERS, CONDENSER WATER PIPEWORKS,

MAKEUP WATER TANK REPLACEMENT, NEW AIR CONDITIONING MAIN
SWITCHBOARD AND ALL RELEVANT WORKS AND,
PHASE 2 – CHILLERS, CHILLED WATER DISTRIBUTION PIPEWORKS,
PUMPS, PLATE HEAT EXCHANGERS AND ALL RELEVANT WORKS FOR
BANGSAR ENERGY SYSTEM (BES) PLANT, BANGSAR, KUALA LUMPUR

CHILLER COMMISSIONING PROCEDURE

Document/Drawing Number: BES-SEG-RHB-PR-COM-002
Revision: 0

1 APPROVED

2 APPROVED WITH COMMENT

3 REJECTED

Prepared by Approved by Reviewed by

Rev Date Status
the the the
Contractor Contractor Engineer
A 25/11/20 IFR – Issue for Review Phoa Khairi Sharil
A1 25/01/21 IFR - Re-Issue for Review Phoa Khairi Sharil
B 01/03/21 IFA – Issue for Approval Phoa Khairi Sharil
0 19/03/21 FIN - FINAL Phoa Khairi Sharil
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1. PURPOSE

The aim of this procedure is to ensure overall quality and safety of the commissioning work for chillers.

2. SCOPE & OBJECTIVE

The Scope covers for pre-commissioning and commissioning procedure for chillers.

3. REFERENCES

This document shall be based on following specification and references:

• Chiller Specification
• Drawings
i. Equipment Layout Ground Floor Drawing BES-SEG-RHB-ME-DR-002
ii. P & ID (Overall Plant) Drawing BES-SEG-RHB-CI-DR-001

4. DEFINITION

EMPLOYER Means BANGSAR ENERGY SYSTEMS SDN. BHD.

ENGINEER Means person appointed by the EMPLOYER to act as engineer for the
purposes of contract
CONTRACTOR Means the person(s) named as contractor in the letter of tender
accepted by the EMPLOYER – SEGATRANS SDN BHD
WORK means DESIGN, SUPPLY, INSTALL, TESTING AND
COMMISSIONING WORKS FOR: PHASE 1 – COOLING TOWERS,
CONDENSER WATER PIPEWORKS, MAKEUP WATER TANK
REPLACEMENT, NEW AIR CONDITIONING MAIN SWITCHBOARD
AND ALL RELEVANT WORKS AND, PHASE 2 – CHILLERS, CHILLED
WATER DISTRIBUTION PIPEWORKS, PUMPS, PLATE HEAT
EXCHANGERS AND ALL RELEVANT WORKS FOR BANGSAR
ENERGY SYSTEM (BES) PLANT, BANGSAR, KUALA LUMPUR
SUBCONTRACTOR Means any person or company approved by the CONTRACTOR, to
whom part of the WORK is subcontracted by CONTRACTOR for the
purpose of carrying out the WORK.
SCHEDULES Means the planning document, including Master Project Schedule,
agreed between the EMPLOYER and CONTRACTOR, for the
execution of the WORKS.
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5. GENERAL INFORMATION

5.1 Design Calculation

Chilled water

Inlet temperature : 14.5℃

Outlet temperature : 5.0℃
Flowrate : 381.1m3/h

Chiller RT = (381.1×1000÷3600) × 4.2 × (14.5-5) = 4,223.86kW = 1,200RT

Cooling Water

Inlet temperature : 30.6℃

Outlet temperature : 35.8℃
Flowrate : 823m3/h

5.2 Equipment

Chiller
Make : Mitsubishi
Model : GART-135
Type : Centrifugal
Cooling Capacity : 1200USRT

Chilled Water
Inlet temperature : 14.5℃
Outlet temperature : 5.0℃
Flowrate : 381.1m3/h

Cooling Water
Inlet temperature : 30.6℃
Outlet temperature : 35.8℃
Flowrate : 823m3/h
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5.3 System Description

There are 10 chillers with a total capacity of 11144RT. 6 of them are brine chillers with total capacity of
6344RT, and the remaining 4 base chillers have the total capacity of 4800RT. Chilled water flow for
base chiller is 381.1m3/h. The chilled water supply temperature is 5oC and the return shall be 14.5oC.
The condenser water supply and condenser water return temperature are 30.6oC and 35.8oC,
respectively.

6. PRE-COMMISSIONING

Pre-commissioning plan for chiller is as below.

Pre-commissioning Activities

Description Employer Contractor TOYO Remarks

(BES) (SEG)
1. Equipment installation physical check W S S
2. Piping installation physical check W S S
3. Air tightness test W S S
4. Evacuating and vacuum test W S S
5. Protective device check W S S
6. Electrical wirings check W S S
7. Lubricating oil charging W S S
8. Refrigerant charging W S S
Legend :
W : Witness Inspection
S : Execute and Submit Inspection

For detail electrical chiller pre-commissioning, please refer to SECTION 5 to SECTION 9 in the attached
vendor’s procedure ‘Installation and Trial Operation Procedure for Mitsubishi Centrifugal Chiller
Model: GART-135’ in Attachment 1.
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7. COMMISSIONING

Commissioning plan for chiller is as below.

Commissioning Activities

Description Employer Contractor TOYO Remarks

(BES) (SEG)
1. Pre-start Operations W S S
2. Preparation for Start-up W S S
3. Chiller Start-up W S S
Legend :
W : Witness Inspection
S : Execute and Submit Inspection

Manual start up can be done by running the chilled water pump, followed by cooling water pump and cooling
tower fan. Then only start chiller manually at control panel. For stopping chiller, stop chiller manually at
control panel, followed by cooling water pump, cooling tower fan and chilled water pump.

For detail electrical chiller commissioning, please refer to SECTION 10 to SECTION 11 in the attached
vendor’s procedure ‘Installation and Trial Operation Procedure for Mitsubishi Centrifugal Chiller
Model: GART-135’ in Attachment 1.

8. ATTACHMENT

ATTACHMENT 1 Installation and Trial Operation Procedure for Mitsubishi Centrifugal Chiller Model:
GART- 135
ATTACHMENT 2 Inspection Checklist & Commissioning Test Form
ATTACHMENT 3 Calibration Certificates for Measuring Instrument
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ATTACHMENT 1

Installation and Trial Operation Procedure for Mitsubishi

Centrifugal Chiller Model: GART- 135
 Contents

1. Specification of Centrifugal Chiller

2. Supervising

3. Installation (general)

4. Notice of Completion of Installation Work

5. Air tightness test (general)

6. Vacuum Test

7. Electrical Wirings Check

8. Charging of Lubricating Oil

9. Charging of Refrigerant

10. Trial Operation

11. Condition of stop

12. Report

Attachment 1 Scope of work

Attachment 2 Schedule for start-up work (to be determined)
Attachment 3 Insulation procedure for the Compressor motor terminals
AttachmentPre-Commissioning
4 Insulation procedure for the Compressor motor terminal box

Attachment 5 Tool list for installation and start-up work

AttachmentCommissioning
6 Notice of completion of installation work
Attachment 7 Refrigerant charge/discharge valve information
Attachment 8 Machine layout & Lifting drawing
This document describes the procedure and cautions for the installation and trial operation of R-134a
Centrifugal Chiller for Phase 2 Chillers for Bangsar Energy System (BES) Plant project, Malaysia.

1 Specification of Centrifugal chiller

Refer to Specification sheet for details.
Customer description TBD BANGSARTBD
ENERGY SYSTEM
TBD SDN BHD
TBD
Chiller model: GART-135
Compressor model: MCG-N3
Cooling capacity 4,219.5 kW / 1,200 USRt
Chilled water spec. Inlet 14.5 deg. C / Outlet 5.0 deg. C, 381.1 m3/h
Cooling water spec. Inlet 30.6 deg. C / Outlet 35.8 deg. C, 823.0 m3/h
Motor spec. Input 719.8 kW / Output 655.9 kW, 50 Hz, approx. 71.0 A , 6.6kV
Quantity 4
Machine No. T20137 T20138 T20139 T20140

2 Supervising (In case of included in the quotation)

2-1 Scope of supply

No. Items Installation by Start-up by

1 Supervisor TOYO CR TOYO CR, MTH
2 Worker (mechanical) SEGATRANS
CUSTOMER SDN BHD SEGATRANS
CUSTOMER SDN BHD

3 Worker (electric) SEGATRANS

CUSTOMER SDN BHD SEGATRANS
CUSTOMER SDN BHD

4 Tools and material SEGATRANS

CUSTOMER SDN BHD SEGATRANS
CUSTOMER SDN BHD

5 Utility (Electricity, water, etc) SEGATRANS

CUSTOMER SDN BHD SEGATRANS
CUSTOMER SDN BHD

6 Working Area SEGATRANS

CUSTOMER SDN BHD SEGATRANS
CUSTOMER SDN BHD

(Notes)
Employer (BANGSAR ENERGY SYSTEM SDN BHD) Representative: SEGATRANS SDN BHD
1) Supervisor (TOYO CR, MTH) does not control a work schedule
2) Supervisor (TOYO CR, MTH) supervises from Air tightness test to Trial operation of the said
chiller and has no responsibility of supplied workers.
2-1) Scope of work
Please refer to the attachment 1.
2-2) Schedule
Please refer to the attachment 2. (To be determined.)
3) Use the check sheets of the Installation and start-up, the Operation records of protective
devices, and the Operation data (MTH authorized mechanic furnishes).
4) Procedures for compressor motor terminals refer to the attachment 3 and attachment 4.
5) Tools refer to the attachment 5.

-2- EGG-05789 R1
3 Installation (general)
3-1 Followings shall be arranged prior to commencement of Installation and Trial Operation.
(1) Foundation for the chiller shall be arranged according to the machine layout drawing.
(2) Service clearance is required for maintenance and overhauling. Tube removal space should
be provided at either end. Please refer to the notes of the machine layout.

3-2 Delivery and Installation

(1) Move the chiller horizontally as much as possible, less than 5 deg. incline.
Apply outside eye-holes of upper part of the tube plates.
Please be careful so that you may not carry out for hanging in diagonally.
Please refer to Attachment 8. About the actual lift instruction, please refer to latest
specification.

・With lifting beam (Following illustrations are for reference.)

R1

The tube plate

HCW009B357

-3- EGG-05789 R1
 ・Without lifting beam (Following illustrations are for reference)

R1

The tube plate

HCW009B358

(2) The first of all, spread the rubber pad on the foundation, and install the chiller on the mat.
(3) To fix with the anchor bolts, put the rubber bushing and washers and then tighten by double
nuts. Please refer to the notes of the machine layout.
(4) Check level by using a clear water hose referring to the punch mark at the center of tube
plate (Incline to be within 1/1000).
(5) Fill out and furnish two copies of the notice of completion of installation work.

3-3 Transfer chiller horizontally (this is a sample method by roller and winch)
After unloading chiller, transfer chiller horizontally and pull by using rollers and winches.
Temporary skid should be spread around foundation base to make flatten surface for chiller
transfer pathway. Temporary skid (or round wood) should be made same height as chiller
foundation height.

Chiller room

Same as
Foundation height

Winch Pulley
HCW073F313
Roller Temporary Skid Foundation base
-4- EGG-05789 R1
 3-4 Jack up Chiller and install on the foundation base
After the chiller has transferred above foundation base, jack up the chiller.
Set rubber mats followed by machine layout drawing, refer to the attachment 8.
Jack positions should be on jack up boss under the chiller.

Jack up Boss

Jack

HCW073F313
Temporary Skid Foundation base Chill roller

3-5 The hanging rail for compressor maintenance

It is recommended to install permanent hanging rails for the time to perform major compressor
maintenance. The vertical position of hanging rail should be above 5 m from the floor.
The horizontal position of the rail should be right above center of gravity.

4 Notice of completion of installation work

Prior to carrying out start-up works, the recording form “Notice of completion of installation work”
should be furnished by installer of the chiller, refer to the attachment 6.
Pre-Commissioning
5 Air tightness test (general)
Procedures:
(1) Open each manual valves to full so that pressure will apply to the whole area of refrigerant
system and oil system, including the instrumentation piping.
(2) Use nitrogen gas for pressurization, and be sure to raise pressure through the pressure
reducing valve. Close the safety valve.
(3) The test pressure to be 1.10 MPa. Check for any leakage with soapy water (ex. Nekar aqueous
solution). (Notes: test pressure is for reference)
(4) Be sure to repair any leakage after discharge nitrogen gas to the atmospheric pressure.
Ventilate thoroughly, or exhaust nitrogen directly to outside to avoid shortage of oxygen.

-5- EGG-05789 R1
 (5) During the pressurization, prohibit access to the work area, and display a sign of
“PRESSURIZE GOING ON”.
(6) When blowing out nitrogen after air tightness test, ventilate thoroughly, or exhaust nitrogen
directly to outside. Open the safety valve.
* In principle use at least two pressure gauge, dial plate should be larger than 75 mm and maximum
scale should be over 1.25 times but within 2 times of the air tightness test pressure.

6 Vacuum Test
(1) Discharge air form the refrigerant / oil system to 665 Pa abs (5 mmHg・abs) or lower by using a
vacuum pump.
(2) After leave as it is more than 12 hours, the change of the vacuum level should be less than 665
Pa abs (5 mmHg・abs).
(3) If the refrigerant is scheduled to be charged two months or more after from the vacuum test,
temporary charge nitrogen gas at pressure about 0.03 MPa (G) and check every month for the
pressure.

7 Electrical Wirings Check

(1) Retighten the terminals in power circuit (high-voltage and low-voltage) and control circuit, check
for any loosen connection or wrong connection. After retightening of power circuit, apply a paint
mark.
(2) Measure the high voltage motor insulation resistance with 1,000 V Megger tester and confirm it
to be 5 MΩ or more.
(3) Measure the insulation resistance of low voltage power circuit and control circuit by using 500 V
Megger and confirm it is 0.5 MΩ or more.
(4) Check the sequences of starter panel and control panel.
(5) Check the operation of protective devices (pressure, temperature and flow rate).
(6) Check the setting rate of timer with the electrical drawings.
(7) Confirm setting of the motor protection (thermal over load relay, 2E relay etc.) at rated current
rate in the starter panel.
Ex: In case of CT rate 50 / 5 A, Motor rated current 30 A
30 x 5 / 50 = 3 A  thermal setting rate
（8） Confirm correct setting of the protection device in the starter panel.
(Current rate is set at rated current, Time scale 7 to 8, scale factor X1)
Ex: In case of CT rate 50 / 5 A, Motor rated current 30 A, current scale factor X0.5
30 A X 5 / 50 X 1 / 0.5 = 6 A  motor relay setting rate

-6- EGG-05789 R1
8 Charging of Lubricating Oil
8-1 Oil supply to the compressor.
Charge lubricating oil before charging refrigerant. Then oil need to be heat up to 60 deg. C.
(1) Manufacturer and product name of the lubrication oil is as follows:

R1 JX Freol α68B (be sure to use the genuine oil.)

Take proper care in handling ester oil because it is extremely hygroscopic.
(2) Lubricating oil shall be charged via oil charge valve under the vacuum condition of 266 Pa abs
(2mmHg・abs) or lower, within 1 hour from being unsealed of the oil can.
(3) After refrigerant is charged, during the operation of the compressor, the oil level should be
between the center of the lower sight glass and center of the middle sight glass.

UPPER SIGHT GLASS

MIDDLE SIGHT GLASS

Rough guide line of the oil level before refrigerant charge
LOWER SIGHT GLASS
Guide limit of the oil level during the operation of the compressor

When the oil level is higher than the centerline of the upper sight glass, which means that the oil
level is too high, oil may spray into the chiller at the time of startup or abrupt load change.
On the other hand, when the oil level is too low, oil pump sucks gas, causing cavitations and this
will sometimes lead to oil pressure decrease and the chiller may be stop.
(Note): However that the oil level may fluctuate more or less according to the changing loads.
Do not confuse this with the oil level abnormality.
(4) In the initial stage of operation, transitional oil level descent is observed. This is because new
refrigerant contains no oil in it. As more of oil is dissolved, the condition stabilizes.
Therefore, in some case it is necessary to replenish the oil after initial charge. But do not exceed
refrigerant replenish over 6 wt%. Be sure to record replenish volume and date.
Aimed amount of oil replenishment shall be 5 wt% of the amount of refrigerant charge. Use the
oil-returning eductor thereafter to recover the oil. For the usage of oil-returning eductor, see the
operation manual. If inappropriate amount of refrigerant is charged, the oil could not be
recovered even by using the evaporator eductor.
In case of over charge adjust it by draining excessive oil. Oil can be drained through the drain
valve during manual operation of the oil pump.

(5) Use the temporarily installed booster pump for any recharge after the refrigerant is charged,
which is applicable during operation.
Pump is not equipped with the chiller. So that prepare oil pump for charging oil.
Specification of the pump: Trochoid-type pump, Theoretical discharge rate more than 4.21 MPa,

-7- EGG-05789 R1
 maximum discharge pressures to be more than 1.5 MPa with motor output 200 W.
Proceed with following procedure
a) Put new oil in the clean vessel. Insert the suction side of a clean hose in to the vessel,
connect discharge hose to the oil charge valve.
b) Operate oil pump manually, open oil charge valve a little, charge oil to the oil tank.
c) Charge up to center of the middle sight glass of oil tank, stop the oil pump and close oil
charge valve then disconnect hose.
d) After completion of oil charge, turn on the oil heater of compressor.
Oil heater will operate on and off automatically in between 60 deg. C to 65 deg. C.
Note: Vent air completely from the temporarily installed piping before charging.

9. Charging of Refrigerant
(1) Check if the temperature of the compressor oil tank is 55 deg. C or higher.
(2) Start the chilled water pump and the cooling water pump, and check if water passes through the
each heat exchanger tubes.
(3) After checking the vacuum of 266 Pa abs (2 mmHg・abs) or lower, charge with gas until the
internal pressure reaches 0.22 MPa or higher.
(4) Then, charge with liquid, filed up to 100% quantity of MTH shop test results. When heating the
charging vessel, use any hot pack or hot water of 40 deg. C or more.
(5) In the charging work, be sure to put on protective tools (goggles, leather gloves), and keep a
well-ventilated place.

Cautions in Handing
Since it is heavier than air, the refrigerant stays at low place when it leaks.
If any unprotected flame is used at the place where large amount of gas is present, the
refrigerant decomposes, and produces harmful gas.
Therefore, be sure to ventilate such a place.
Charging vessel shall be stored at 40 deg. C or lower.

Commissioning
10. Trial operation
(Note): Prior to starting work, refer to the schedule.
10-1 Check of the Rotational Direction of Main Motor
(1) Supply main-voltage power.
(2) Start the chilled water pump and the cooling water pump.
(3) Start the oil pump, and check the oil supply and oil tank internal pressure.
(4) Select the place of operation to the Local, and turn ON the START key.
(5) When the main motor runs for 2 to 3 sec, stop it immediately, and check the rotational direction
through the sight glass mounted at rear end the of the motor, which is to be counter-clockwise.
-8- EGG-05789 R1
 (Note): 1. If any start instruction causes chattering, the contacts may be fused, causing
malfunction or fire.
2. To check secondary side CT is normal, be sure to check if the ammeter needle
reacts.
10-2 If the temperature of the cooling water is lower than 15 deg. C, throttle the flow rate of the
cooling water, and maintain the condensing pressure to 0.64 MPa or higher during operation.
10-3 If the temperature of the chilled water is higher than 30 deg. C, throttle the flow rate of the
chilled water toward the limit of Half, and maintain the evaporating pressure to an appropriate
level 0.23 to 0.39 MPa or lower during operation. In the first operation, open the vane manually
to 10%, check the pressure, temperature and noises, and then sample data. Open the vane
gradually to increase the load. When throttle the flow rate of the chilled water, check and adjust
a value of water failure relay. After recovery of the flow, be sure to return the value before
adjusting.
10-4 Keep the bearing lubrication temperature within 35 deg. C to 45 deg. C by adjusting the
temperature control valve expansion valve for refrigerant cooled oil cooler. Be sure to avoid
extreme cooling.
10-5 Appropriate bearing lubrication pressure shall be the oil tank internal pressure plus 0.20 to 0.25
MPa. Adjust this by using the oil pump relief valve.
After such adjustment, tighten the cap of the relief valve firmly.
Since no pressure gauge is installed inside the oil tank, install such a pressure gauge
temporarily in the oil line for the oil pressure switch-low pressure side.
10-6 Check the operation of the suction vane and the bypass valve with adjusting open and close
timing of the bypass valve not to hunting phenomenon when low load operation.

100%

BCV
Bypass
Valve
VM
Opening For reference

0 5% 20% 100%
Suction vane Opening
Operation of suction vane / bypass valve

10-7 Check the operation of the currency limitation control of chiller.

10-8 Check chilled water outlet temperature control is operating under condition of automatic
operation of suction vane.
10-9 Check the amount of refrigerant is appropriate in case of high load operation.
(1) As seen from the evaporator sight glass, the refrigerant splashes around on the upper
-9- EGG-05789 R1
 stage of the tube.
(2) Main motor current shall not fluctuate.
(3) Suction temperature and discharge temperature should not fall too much.
(Higher than condensing temperature ＞ + 3.5 deg. C)
10-8 Measure the vibration of the each area of the compressor and motor, and check for any
abnormality.
10-9 Collect the operation data, and check for any abnormality in each part.
10-10 Check cooling refrigerant of the main motor is splashing sufficiently through at the sight grass.
If any clogging occurs in the dryer installed in the chiller line, it causes insufficient cooling. When
this dryer start to be clogged, which causes definite temperature difference between inlet and
outlet of the clogging point, replace the dryer in such a case.

11. Condition of stop

(1) Close the suction vane manually to the opening of 10%, and stop the compressor.
Then, measure the stop time of the main motor and the time of oil pump residual operation.
(2) Check if the cooling water pump stops at the same time as the compressor stops.
(3) Check if the chilled water pump and the oil pump operate residually for 100 sec after the
compressor stops.
Note:
If power fail for a long time after charging the refrigerant:
(1) Secure the temporary power source if possible, and prevent power failure.
(2) If it is difficult to secure a temporary power source, be sure to energize the oil heater 12 hours or
more before operating the chiller, and raise the temp of the oil tank to 55 deg. C or higher. And
operate the oil pump manually 1 hour before, then check the oil pressure and stir the inside of
the oil tank.

12. Report
(1) Issue commissioning report.

- 10 - EGG-05789 R1
 Commissioning
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ATTACHMENT 2

Inspection Checklist & Commissioning Test Form

 1 Installation Check Sheet (1/2)

Order Witnessed by
Delivered to Service agent
Purchaser Bangsar Energy System Sdn Bhd Responsible engineer
Installing company Completion date
Model of chiller Machine No.
Model of compressor Name of customer Bangsar Energy System Sdn Bhd

One-block, divided into two

Delivery form Thermal accumulator Provided/Not provided
or specially divided
Delivered refrigerant kg
Delivered oil L
Omission in delivery

Work type Check item Cautions Check Remarks

1. Acceptance ・Is the visual check of Is there any damage of □
inspection appearance completed omission caused in transit?
normally?
・Isn’t there any loss of Anchor bolt, vibration-proof □
accessories? rubber or spring mat, divided
articles, spare parts, etc.
2. Installation ・Are the direction of the Negotiations shall be held with □
chiller, model and machine the customer previously.
No. correct?
・Is the vibration-proof rubber See the drawing of the □ Spring mat is
or spring mat spread under foundation and the layout of optional.
the heat exchanger unit? the spring mat.
・Is the heat exchange level A tube plate punch mark or any □
within 1/1000? separate reference mark shall
be provided, and the
measurement shall be carried
out by the water levels.
( ) ( )

Condenser

Evaporator

( ) ( )
Unit: mm
・Was the absence of foreign Prior to assembly, be sure to □ (Divided into
matter checked in assembly? service the flange unit and two/specially
blow the pipings. divided in
shipment)
・Is the positioning metal Installation shall be □ (Specially
piece fixed firmly in the accomplished by the tube plate divided in
divisions of the heat joint surface of the evaporator shipment)
exchanger ? and condenser (inside).

Check marks － □Not required 〇 □OK × □NG 〇 □OK if adjusted or repaired
□Work completed
 1 Installation Check Sheet (2/2)

Work type Check item Cautions Check Remarks

・Is the tube plate joint To be fixed by welding to the □ (Specially
surface in the divisions of bevel (outside) in the tube divided in
the heat exchanger fixed by plate joint surface of the shipment)
welding? evaporator and condenser.
・Are the direction of the Never hold the machine □ (Completed
motor panel and its laterally at carry-in products
machine No. correct, and is shipped)
the machine installed at the
specified place?
・Is the installation level of The doors shall open or close □
the motor panel correct? smoothly.
・Are the components, which If the motor panel is curried-in □ (Panel
were removed when the laterally, since the arc components
motor panel was extinguish chamber of the divided in
transported laterally, high-voltage electromagnetic shipment)
replaced correctly? contactor, starting transformer See Installation
For details, see the motor and phase advancing capacitor /Trial Operation
panel check sheet. are previously removed and Procedure
delivered, be sure to (DPE・00075).
accomplish recovery.
・Are the openings in the The secondary electrical wiring □ (Divided into
electrical wirings is opened when divided in two/specially
reconnected normally? shipment. Therefore, re- divided in
establish the wiring by referring shipment)
to the electrical drawings.
3. Pneumatic test ・Pressurize with nitrogen Machine shipped as one □
(1.10 MPa(G), and check if block/specified equipment shall (Divided in
there is no leakage. be inspected autonomously. shipment)
Machine divided in shipment
requires the certificate of test
approval issued separately.
Pressure gauge used in the
test shall be φ75 or more, and
the range shall be 1.5 MPa (G) (Divided in
or more and 2.0 MPa (G) or shipment)
less. Two units or more of
such pressure gauge shall be
used.
4. Vacuum test ・When left for 12 hours or If any drop of vacuum degree is □
more under a high level of observed, repeat the
vacuum 665 Pa abs or less, pneumatic test.
the drop of vacuum level
shall be 665 Pa or less.
5. Curing ・When stored for a long Long-term storage shall last 2 □
time, charge nitrogen (0.03 months or more for reference.
MPa (G)).
・The customer shall be Take care so that the □
requested to do curing measuring steel pipe or electric
control. instrumentation may not be
damaged, and that no air may
intrude inside.
6. Special notes

Check marks － □Not required 〇 □OK × □NG 〇 □OK if adjusted or repaired
□Work completed
 2-1 Start-up Check Sheet (1/4)

Order Witnessed by
Delivered to Service agent
Purchaser Bangsar Energy System Sdn Bhd Responsible engineer

Installing company Completion date

Model of chiller Machine No.
Model of compressor Name of customer Bangsar Energy System Sdn Bhd

Work type Check item Cautions Check Remarks

1. Retesting vacuum ・When left for 12 hours or If any drop of vacuum degree □ Pressure before
more under a high level of is observed, repeat the left
vacuum 665 Pa abs or pneumatic test, and repair the ( Pa abs)
lower, the drop in the level leaking section. Pressure after
of vacuum shall be 665 Pa left
or less. ( Pa abs)
2. Charging oil ・Lube oil shall be specified When opening the oil can, □ Amount of
by MHI. check for any foreign matter charged oil
FREOL α68B being included. ( )L

・Turn ON the oil heater □

power before charging the
refrigerant.
3. Check of water ・Check if the inlet/outlet □ The heat
piping piping of the chilled water recovery type
and cooling water is has a hot water
correct. piping.
・Check if the piping applies □
no stress on the main unit.
・Flow the chilled water and □
cooling water through the
pipes line, and check for
any water leak or vibration.
・Check if the specified flow Measure the pressure loss of □ Diff. Press. of
rate is obtained. the water between the inlet/ chilled water
outlet of the heat exchanger. Specified value
Since the flow of chilled water [ kPa ]
Actual value
affects the expansion valve
[ kPa ]
control by microcomputer
Diff. Press. of
board, adjust it as set. If cooling water
deviating, consult the Services Specified value
Section. [ kPa ]
Actual value
[ kPa ]
Diff. Press. of
hot water
Specified value
[ kPa ]
Actual value
[ kPa ]

Check marks －□Not required 〇□OK ×□NG 〇□OK if adjusted or repaired
□Work completed
 2-1 Start-up Check Sheet (2/4)

Work type Check item Cautions Check Remarks

4. Charging ・Is the level of internal Be sure to put on protective □ The level of
refrigerant vacuum correct? tools. internal vacuum
266 Pa abs or lower Be sure to ventilate properly. ( Pa abs)
・Check the amount of the Do the chilled water and □ ( kg)
refrigerant charged. cooling water flow, or is the
exhaust water blown?
Charge amount shall be 100%
of the actual amount in plant
operation.
Concerning the amount of
charged refrigerant, be sure to
measure the mass of bomb
before/after the charge work
(Since the charge amount is an
important value in maintenance
control, be sure to record it).
Empty bomb shall always be
returned to manufacturer.
5. Sequence check ・Is the wiring between the Prior to receiving power, clean □
motor panel and the motor the inside of the motor panel
terminals installed and check for anything in
correctly? contact with the unit.
・Is any condensation- □
preventive measure
provided in the motor
terminals and KLIXON
thermo terminals?
・Is the wiring between the □
motor panel and the
operation panel installed
correctly?
・Is the operating power Be sure to check the operating □
voltage normal? power voltage by voltmeter
before the control power is
turned ON.
・Are the start/stop signal □ The heat
and the interlock signal of recovery type
the chilled water pump and has a hot water
cooling water pump issued pump.
properly?
・Is the operation of the Shown in the attached data. □
protective devices
checked?
・Is the linkage test with the □
motor panel completed
normally?
・Is grounding performed Main motor, motor panel and □
properly? operation panel
・Are correct values set for Shown in the attached data. □
the timers?
・Is the main motor insulated Check this by using a 1000V □ ( MΩ)
properly? megger. High-voltage motor:
5MΩ or more
・Is the oil pump insulated Check this by using a 500V □ ( MΩ)
properly? megger. Low-voltage line:
0.5MΩ or more
・Is the oil heater insulated Same as above □ ( MΩ)
properly?

Check marks □
－ Not required □OK
〇 □
× NG □
〇 OK if adjusted or repaired □

Work completed
 2-1 Start-up Check Sheet (3/4)

Work type Check item Cautions Check Remarks

5. Sequence check ・Is the terminal unit of the Check all the screws that can □ See the service
electrical wiring re- be re-tightened without wiring information
tightened properly? or disassembly (All the power 10-C002-RO.
circuits shall also be checked).

6. Others ・Is the cold insulation work □ Specified

finished? equipment is
・Is the finish painting □ delivered after
completed? completing
・Are the name of refrigerant As per High-pressure Gas □ these steps of
and the direction of flow Safety Law, for reference. work at shop.
indicated properly? However, re-
・Is the valve open/close As per High-pressure Gas □ checks shall be
indicated properly? Safety Law, for reference. essential.
・Does the certificate of the As per High-pressure Gas □ Specified
pressure test/pneumatic Safety Law, for reference. equipment shall
test conform to the name be excluded.
plate?
7. Preparation for test ・Carry out pipe line check. In the check, be sure to use the □ Also create and
run refrigerant/oil pipe system record data in a
diagrams in the final drawings. separate valve
・Check the valve □ open/close
open/close. check list.
8. Trial operation ・Is the high-voltage power Check this by using voltmeter. □ ( V)
supplied?
・Are set values for Check this by the list of settings □ Oil tank
microcomputer board for each machine. temperature
checked? ( ℃)
・Does the motor turn in Operate for 2～3 sec. □ Oil tank internal
correct direction Be sure to operate the chilled pressure
(counter-clockwise as seen water/cooling water pumps. ( MPa(G))
from the rear end of the
motor)?
・Is the oil temp appropriate □
(45℃ or higher)?
・Is the oil pressure To check the oil tank internal □ Oil pressure
appropriate (oil tank pressure, install a pressure ( MPa(G))
internal pressure gauge temporarily.
+ 0.25 - 0.30 MPa (G))?
・Is the oil level correct? This shall not rise to the upper □ Differential
sight glass pressure
(checked during operation). ( MPa(G))
〇
〇
〇
・Check of lubrication of the Check from above or below the □
bearing in the back of motor sight glass in the back of
・Check of motor cooling motor.
refrigerant □
・Do the vane motor and hot □
gas valve work normally?
・Does the expansion valve □
work normally?
・Is there any carry-over If any carry-over occurs, the □ Within ± 5% of
happening? ammeter will falter. the rated current

Check marks □Not required

－ □OK
〇 ×
□NG 〇
□OK if adjusted or repaired □

Work completed
 2-1 Start-up Check Sheet (4/4)

Work type Check item Cautions Check Remarks

8. Trial operation ・Isn’t the evaporating Insufficient amount of □
pressure too low? refrigerant or low temp of
cooling water in high load
・Doesn’t the voltage of the Within ±5% of the rated □ ( V)
main motor fluctuate? voltage
・Is the cooling water inlet The fluctuation of the cooling □ (Within ℃)
temp stabilized? water inlet temp should be
within 4℃.
・Is the chilled water outlet □ ( ℃)
temp controlled stably?
・Is the oil supply temp. □ ( ℃)
adequate (30℃～45℃)?
・Measure the race time Stops at the min. opening of □ ( sec)
when stopped. the vane.
If any race time is longer than
the time of the oil pump stop
timer, adopt a longer timer
time.
・Is the flow normal in the If no air bubble can be found in □
condenser liquid pool? the liquid pool sight glass, the
expansion valve could be too
closes. Adjust it in the open
direction, therefore. Also check
if the flow of chilled water is as
specified.
・Is hot support □
communication performed?
・Is there any large □
difference from plant
operation data? Is the
heat balance met?
9. High-pressure gas ・Are the rehearsals of the □ Specified
completion high-pressure cut and low- equipment shall
inspection, for pressure cut completed? be excluded.
reference ・Is the unit approved in the □ Inspection date:
high-pressure gas
completion inspection? Specified
equipment shall
be excluded.
10. Education ・Is the operation explained? Date:

11. Special notes

Check marks □Not required

－ □OK
〇 ×
□NG □OK if adjusted or repaired
〇 □

Work completed
 2-2 Operation Records of Protective Devices (including partial control)

Type of Target set value Operation value

Name Unit Check Remarks
trip OFF ON OFF ON
High, Condenser Trip / MPa(G) 1.01 0.81 □
pressure Soft trip MPa(G) 0.96 0.81

Low, Evaporator Trip / MPa(G) 0.18 0.28 □

pressure Soft trip MPa(G) 0.19 0.28

Low, Evaporating Trip ℃ □ Option

refrigerant temp.

Low, Differential oil Trip MPa(G) 0.20 0.225 □

pressure

High, Oil tank temp. Soft trip ℃ 75 70 □

Failure

Low, Oil tank temp. Soft trip ℃ 35 40 □

Low, Supply oil temp. Soft trip ℃ 75 70 □

Low, Chilled water Trip / ℃ 2.0 7.0 □

outlet temp. Soft trip ℃ 3.0 7.0

Low, Chilled water 63EW kPa(G) □

flow rate

Low, Cooling water 63CW kPa(G) □

flow rate

Oil heater thermo OHS 65 60 □

Control

Part load thermo □

Check marks □
－ Not required 〇 OK
□ × NG
□ 〇 OK if adjusted or repaired
□
Work completed
□
 2-3 Operation Data

Customer: Bangsar Energy System Description: Model: Machine No. T

Sdn Bhd
Date of operation Date . . . Start : Stop :
Recording No. Specification
ｎ
Recording time
Opening of vane %
Opening of bypass valve %
nd
Opening of 2 vane (or diffuser) %
Opening of high-stage expansion valve %
Opening of low-stage expansion valve %
Voltage Ｖ
Motor

Current Ａ
Frequency Hz
Input kW
Suction temperature ℃
Discharge temperature ℃
Compressor

Oil tank oil temperature ℃

Oil pressure MPa(G)

Oil level 〇〇
〇
Oil supply temperature ℃
Evaporating pressure, EP MPa(G)
Evaporating temperature ℃
Saturation temperature ℃
Evaporator

Chilled water inlet temperature ℃

Chilled water outlet temperature ℃
Difference in chilled water temp. ℃
Chilled water flow rate m3/h
Chilling capacity kW
Condensing pressure MPa(G)
Condensed liquid temperature ℃
Saturation temperature ℃
Condenser

Liquid pool level 〇

Cooling water inlet temperature ℃
Cooling water outlet temperature ℃
Difference in cooling water temp. ℃
Cooling water flow rate m3/h
Heat capacity kW
Economizer pressure MPa(G)
Econom

Saturate temperature ℃
izer

Liquid level mm

Heat balance
Setpoint of chilled water outlet ℃ Chiller Running Cnt Hr
Setpoint of demand control % COMPR Running Cnt Hr
 Commissioning
Doc No BES-SEG-RHB-PR-COM-002
CHILLER COMMISSIONING PROCEDURE Revision 0

Page Page 8 of 8

ATTACHMENT 3

Calibration Certificates for Measuring Instrument