STERLING AND WILSON PVT.

LTD

MATERIAL / SAMPLE SUBMISSION & APPROVAL SHEET

DANGOTE REFINERY & PETROCHEMICAL PROJECT (DRPP)

PROJECT NAME :
BUILDING WORKS - V PACKAGE EQUIPMENTS
CLIENT :

M/s. DANGOTE PETROLEUM REFINERY AND PETROCHEMICALS,

LFZ
MEP CONSULTANT :

ENGINEERS INDIA LIMITED

Submittal / Data Sheet Ref. No. : A545-4103-9030-VD-COMM-SW54 Rev. No.: R2

Date of Submission : 02-11-2020 Approval Required By : 08-11-2020
Spec. ref. / Drg. Ref. : ----
B.O.Q. ref. : ----
Material Description : FAT FOR VAM MACHINE
Manufacture Name : THERMAX
Applicable Service : AHU(CHILLED &CONDENDSER VALVE) Date Material required on site :
Area of Use : PROJECT WIDE
Any Other Remarks / Notes By SW :

Attachments / enclosures :
 Catalogue  Drawing  Sample  Material Specification

From : Sterling and Wilson Pvt. Ltd

Prepared By : PRANAV ANAND
Company Date : 16.12.2019
Seal :
Designation : Engineer

Engineers /
Consultant’s
Comments:
Status :
 Approved  Approved with
comments  Revise And resubmit
From :
DANGOTE REFINERY &
From :
PETROCHEMICAL PROJECT (DRPP)
ENGINEERS INDIA LIMITED
BUILDING WORKS - V PACKAGE
EQUIPMENTS
Name :
Date :

Signature /
Company Seal :

Doc. A545-4103-9030-VD-COMM-SW54 Rev. R2

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 FAT FOR VAM MACHINE

INDEX

SR.
DESCRIPTION PAGE NO
NO

1.0 FAT FOR VAM MACHINE 03-08

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 FAT FOR VAM MACHINE

Sr. Comments on R1 Revision SW / Thermax Compliance

No.

01. Minimum Six reading shall be taken – Complied

Comment Shall be Complied

02. Five readings out of Six Readings – Complied

Comment Shall be Complied

Sr. Comments on R1 Revision R0 SW / Thermax Compliance

No.

01. FAT of VAM shall be consucted with actual Noted.

Job PLC. Same shall be conducted as per Separate FAT
for PLC submitted in Instrumentation.

02. Minimum Six reading shall be taken Proposed Three Readings as standard practice
of factory
03. Five readings out of Six Readings Proposed 2 readings out of 3 readings as per
standard practice of factory
04. Interval shall be kept minimum 30 minutes Comply
between readings

05. Specify Unit Comply

06. CAPACITY > 99 % instead of 97% Comply

07. Noise level shall also be recorded and the Absorption chiller is a static equipment and
same shall be within acceptance limits. doesn’t make much noise like Electrical chillers.
Also our testing set-up is there along with
manufacturing inside the factory, so it is not
possible to check noise level only for the chiller.

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 Customer Name M/S. STERLING AND WILSON (DANGOTE)
Document Name Factory Performance Test Procedure for Steam Fired Absorption Machine
Document Type Procedure Document No. CZSFPTP001 Rev. No. 3
Machine Model Serial Number Page 1 of 6
Prepared By M. Jayachandran Department Cooling Engineering C&H Division

Document Name:
Factory Performance Test Procedure
for Steam Fired Absorption Machine

Document No:
CZSFPTP001_3

3 02.11.2020 M.J K.S.V P.B As per customer requirements

2 30.09.2020 M.J K.S.V P.B As per customer requirements
1 22.04.2020 M.J K.S.V P.B Sricity Factory
0 10.01.2013 K.S.V R.B R.B Chinchwad Factory
Rev. No. Date Prepared Checked Approved Description

NOTE: THIS DOCUMENT IS THE PROPERTY OF THERMAX LTD AND MUST BE RETURNED ON REQUEST. IT IS SUBMITTED AS CONFIDENTIAL INFORMATION IN
CONNECTION WITH ENQUIRY, TENDER, ORDER OR CONTRACT. IT IS NOT TO BE USED FOR ANY OTHER PURPOSE OR ORDERED NOR MAY IT BE COPIED OR LENT
WITHOUT OUR AUTHORITY IN WRITING.
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 Customer Name M/S. STERLING AND WILSON (DANGOTE)
Document Name Factory Performance Test Procedure for Steam Fired Absorption Machine
Document Type Procedure Document No. CZSFPTP001 Rev. No. 3
Machine Model Serial Number Page 2 of 6
Prepared By M. Jayachandran Department Cooling Engineering C&H Division

Objective To confirm the cooling capacity and the heat input required for the steam fired
vapour absorption machine at rated chilled water & cooling water temperatures;
rated steam pressure & rated chilled water, cooling water & steam flow rates.

References 1. JIS B 8622 : 2016 – Japanese Industrial Standard for Absorption

Refrigerating Machines

Preparation 1. The vapour absorption machine will be hooked on to the test bay. The Shell
side of the vapour absorption machine will be vacuumised, after which the
refrigerant (water) & LiBr solution will be charged into the machine. The
instruments and control panel will be installed on the machine. Temporary
cabling will be done to hook up instruments to the control panel. Metal
hosepipes / Temporary piping will be done to connect chilled water, cooling
water, steam and condensate circuits of vapour absorption machine to the
supply / return headers of the test bay.

2. Chilled water outlet from the vapour absorption machine will be taken to a
loading tank, where its temperature will be increased using cooling water
and/or steam to attain the required chilled water inlet temperature. Chilled
water pumps then pump this chilled water through the vapour absorption
machine.

3. Cooling water is supplied from the cooling tower to the vapour absorption
machine using the cooling water pumps. The cooling water inlet temperature
is maintained by operating the cooling tower fans and/or adjusting their
speed.

4. Steam required for the vapour absorption machine is supplied from the
boiler. Rated steam pressure will be maintained at the inlet of the steam
control valve by adjusting the fuel firing rate and also by the use of Pressure
Reducing Station. The steam condensate from the vapour absorption
machine is taken to a condensate tank.

5. The rated chilled water and cooling water flow rates will be maintained
through the respective circuit. The chilled water and cooling water flow rate
will be measured using a flow meter (Orifice plate with DP transmitter type).
The flow rate will be calculated as per EN ISO 5167-2 2003 standard and will
be displayed on the SCADA screen.

6. Chilled water and cooling water temperatures will be measured using PT-
100 RTD sensors mounted on the vapour absorption machine inlet/outlet
nozzles and the readings will be displayed on SCADA.

Procedure 1. Machine will be tuned for its rated capacity, ensuring that the water at rated
flow and temperature is pumped through all circuits.

2. Since
Doc. A545-4103-9030-VD-COMM-SW54 Rev.it R2
isnot practically possible to adjust and maintain the exact rated
water flow rates, it will be adjusted within a variation of ± 5% of rated.

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 Customer Name M/S. STERLING AND WILSON (DANGOTE)
Document Name Factory Performance Test Procedure for Steam Fired Absorption Machine
Document Type Procedure Document No. CZSFPTP001 Rev. No. 3
Machine Model Serial Number Page 3 of 6
Prepared By M. Jayachandran Department Cooling Engineering C&H Division

3. The machine will be running under steady state condition. The steady state
condition means maintaining the chilled water outlet temperature and cooling
water inlet temperature within ± 0.5°C of rated.

4. Steam pressure will be maintained within ± 0.2 kg/cm2(g).

5. During this time, the chilled water and cooling water flow rate should not vary
more than ± 5% from that of rated condition.

6. After such steady state is observed, a set of readings will be taken as per
format given in the following pages. All the fields in the format have to be
necessarily filled.
R2 7. Six such readings will be taken at an interval of approximately 30 minutes
and the necessary calculations will be done for determining the capacity and
steam consumption.

8. If five readings out of six observations are found to be within the acceptable
standards, then the performance test at full load is said to be completed.

9. However, if more than one reading is found to be beyond acceptable

standard, the procedure for six readings will be repeated.

Calculations:

Cooling Capacity
Cooling Capacity (TR) =

Where,

= Chilled water density (kg/m3)

= Chilled water flow rate (m3/hr)
= Average specific heat capacity of chilled water (kcal/kg°C)
= Difference between chilled water inlet and outlet temperature (°C)

Steam consumption 1. The gross steam consumption will be taken from the Steam flowmeter
(vortex type) reading displayed on the SCADA screen.

2. Insulation losses: Since the machine will not be insulated during trials,
excess steam flow has to be given to cover for heat losses due to convection
and radiation from the machine surface.

3. Net steam consumption = Gross steam consumption – steam consumption

to cover insulation loss.
Doc. A545-4103-9030-VD-COMM-SW54 Rev. R2
4. Net specific steam consumption = Net steam consumption / cooling capacity

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 Customer Name M/S. STERLING AND WILSON (DANGOTE)
Document Name Factory Performance Test Procedure for Steam Fired Absorption Machine
Document Type Procedure Document No. CZSFPTP001 Rev. No. 3
Machine Model Serial Number Page 4 of 6
Prepared By M. Jayachandran Department Cooling Engineering C&H Division

Acceptance Standard 1. Unless otherwise specifically mentioned in the contract with customer, the
following will be considered for acceptance.

a) Capacity > 99%

b) Net Specific Steam consumption < 105%

2. The capacity should be more than or equal to capacity mentioned in the

contract (subject to above tolerance) for at least five readings out of six.

3. The net steam consumption for said five readings should be less than or
equal to that mentioned in the contract (subject to above tolerance)

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 Customer Name M/S. STERLING AND WILSON (DANGOTE)
Document Name Factory Performance Test Procedure for Steam Fired Absorption Machine
Document Type Procedure Document No. CZSFPTP001 Rev. No. 3
Machine Model Serial Number Page 5 of 6
Prepared By M. Jayachandran Department Cooling Engineering C&H Division

PERFORMANCE TEST READING FORMAT

Client : Doc No : CZSFPTP001

Model / Sr. No. : Rev. No : 3
Date :

Sr Acceptance
Description UOM Rated I II III
No Standard
1 Time HH:MM
CHILLED WATER
2 Chilled water inlet temperature °C
3 Chilled water outlet temperature °C ± 0.5°C
4 Chilled water flow rate m3/hr ± 5%
5 Pressure drop kg/cm2 ± 10%
COOLING WATER
6 Cooling water inlet temperature °C ± 0.5°C
7 Cooling water outlet temperature °C
8 Cooling water flow rate m3/hr ± 5%
9 Pressure drop kg/cm2 ± 10%
STEAM
10 Steam pressure at Steam control valve kg/cm2(g) ± 0.2 kg/cm2(g)
11 Steam flow rate kg/hr
12 Steam condensate temperature °C 80 - 100°C
13 HTG / Generator temperature °C
RESULT
14 Cooling Capacity TR > 99%
15 Gross steam consumption kg/hr
16 Steam consumed to cover insulation loss kg/hr
Net Steam consumption for insulated
17 kg/hr
machine
18 Net Specific steam consumption kg/hr/TR < 105%

Testing Witnessed by

Thermax Ltd For Customer -

Testing Engineer -
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Page 8 of 10
 Customer Name M/S. STERLING AND WILSON (DANGOTE)
Document Name Factory Performance Test Procedure for Steam Fired Absorption Machine
Document Type Procedure Document No. CZSFPTP001 Rev. No. 3
Machine Model Serial Number Page 6 of 6
Prepared By M. Jayachandran Department Cooling Engineering C&H Division

PERFORMANCE TEST READING FORMAT

Client : Doc No : CZSFPTP001

Model / Sr. No. : Rev. No : 3
Date :

Sr Acceptance
Description UOM Rated IV V VI
No Standard
1 Time HH:MM
CHILLED WATER
2 Chilled water inlet temperature °C
3 Chilled water outlet temperature °C ± 0.5°C
4 Chilled water flow rate m3/hr ± 5%
5 Pressure drop kg/cm2 ± 10%
COOLING WATER
6 Cooling water inlet temperature °C ± 0.5°C
7 Cooling water outlet temperature °C
8 Cooling water flow rate m3/hr ± 5%
9 Pressure drop kg/cm2 ± 10%
STEAM
10 Steam pressure at Steam control valve kg/cm2(g) ± 0.2 kg/cm2(g)
11 Steam flow rate kg/hr
12 Steam condensate temperature °C 80 - 100°C
13 HTG / Generator temperature °C
RESULT
14 Cooling Capacity TR > 99%
15 Gross steam consumption kg/hr
16 Steam consumed to cover insulation loss kg/hr
Net Steam consumption for insulated
17 kg/hr
machine
18 Net Specific steam consumption kg/hr/TR < 105%

Testing Witnessed by

Thermax Ltd For Customer -

Testing Engineer -
Doc. A545-4103-9030-VD-COMM-SW54 Rev. R2

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 No Comments

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