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MARINE VESSEL HI-FOG SYSTEMS

SPU Unit Commissioning Report Document Reference: SOP F.08.101

Project Number System Description Commissioning Engineer Project Manager Classification Authority Commissioning location and date

Commissioning Report HI-FOG SPU-Unit

FM040 Date:12.10.2005

INDEX

1. Introduction 2. Safety 3. Pre-Conditions for system Commissioning 4. Pre-Commissioning Inspection 5. System Start Up Procedures 6. Commissioning Tests 7. Third Party Approval and Acceptance Tests Attachments: 1. Commissioning test protocol for HI-FOG in accommodation areas 2. Commissioning test protocol for HI-FOG in machinery spaces

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

1.

Introduction 1.1. This manual is provided for use by trained and Marioff authorised commissioning engineers only. 1.2. The function of this manual is to enable a safe and efficient method of undertaking Hi-fog sprinkler system start up and commissioning, with a specific regard to the safety of persons and equipment which may be in the vicinity of the system being tested. All information detailed is for use by qualified personnel only and is to be used in conjunction with component manufacturers and commissioning engineers work procedures. 1.3. Marioff Oy and or their representatives cannot be held responsible for systems installed incorrectly due to non adherence with the relevant installation guidelines and the relevant certifying authorities requirements. 1.4. All the information contained herein is confidential and proprietary to Marioff Oy and it shall not, in whole or in part, be reproduced, copied, disclosed or used as the basis for manufacture or sale without prior written consent of Marioff Oy.

HI-FOG is a registered trademark of Marioff Oy. Copyright 1997. Marioff Oy

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

2.

Safety 2.1. Hi-fog water mist systems comprise of mechanical and electrical components and also employs high pressure pumps and nitrogen cylinders for water pressurisation, it is therefore imperative that all safety issues be addressed before the carrying out of any system pressurisation or testing. 2.2. Care must be taken to ensure that all relevant procedures are followed all of which should be in accordance with recognised national codes of the territory of installation, and that only competent, appropriately trained personnel fully converse with the equipment being tested, are permitted to carry out system commissioning. 2.3. It is the responsibility of the system installation company to ensure that the installed distribution pipework has been pressurised to the minimum required test pressure of 210 bar. All pressure test results should be documented and be made available for review by the supervising commissioning engineer. 2.4. It is the responsibility of the system installation company to ensure that the electrical installation has been carried out in accordance with the recommendations of Marioff Oy and the relevant minimum site specific requirements. All electrical test documentation should be made available for review by the supervising commissioning engineer.

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

3.

Pre-Conditions for System Commissioning 3.1. In order that the Hi-fog system can be commissioned and tested, the following tasks/equipment should be completed supplied by the customer/installer. (Where applicable). 3.2. All distribution pipework should be completed and pressure tested in accordance with the pressure test requirements. All pressure tests should be documented any such documents should be available for inspection by the commissioning supervisor, prior to commissioning. 3.3. All sprinklers should be in place or alternatively be plugged with the correct blanking plugs supplied. 3.4. All fresh water supply pump(s) should be in place and fully piped in accordance with the relevant installation requirements. 3.5. A source of clean fresh water shall be available, and in sufficient quantity so as to allow full system testing. 3.6. All high pressure pump units and nitrogen/water cylinders should be in place and adequately secured. 3.7. All nitrogen actuation cylinder valves to be fitted. (Do not open nitrogen cylinder valves). 3.8. All interconnection pipework between the pump unit, distribution pipework, and the nitrogen/water cylinder bank should be completed and pressure tested. 3.9. All bilge/overboard pipework should be completed. 3.10. Stand-by pump to be connected to a permanent clean air 4 bar minimum supply, (Isolated, Do Not Open). 3.11. All high power cabling must be completed and insulation tested. All cables to be suitably marked and identified. 3.12. Main power supplies to be made available (Isolated), for immediate use. 3.13. All low power alarm and signalling cabling to be completed and tested. (point to point) All cabling to be suitably marked and identified.

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

3.14. All equipment to be properly earthed in compliance with the latest edition of the local electrical regulations. 3.15. All section valves to be securely mounted and clearly identified. 3.16. Where applicable foam cylinder(s) to be secured, piped and filled, (Refer to Marioff procedures for foam type and quantities). Note: Not all pre-conditions are required to be completed to partially test the system, however unavailability or non-completion of all of the above will delay the full commissioning of the system.

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

4.

Pre-Commissioning Inspection It is the responsibility of the commissioning engineer to independently carry out the following pre-commissioning inspection. Classification Authority or Client Representative does not need to participate at this stage. Note: All deviations/damages must be recorded, and where necessary all remedial work must be completed before system commissioning.

Function 1. Inspection of distribution pipework pressure test certificates 2. Check all aspects of the pump unit installation against the relevant drawings. 3. Visual check of the pump unit installation. Fix and record any physical damage or deviations. 4. Visual inspection of the electrical cable installation, checking cable markings, type etc. 5. Visual inspection of nitrogen/water cylinder bank. 6. Visual inspection of nitrogen cylinder pressure switch connection. 7. Visual inspection of all section valves. Check that all valves are suitably positioned so as to allow access to the isolation facility, pressure gauge and test point. Check that valves electrical component voltages are correct. 8. Visual inspection of fresh water pump unit and associated supply pipework. Check against system drawings.

Completed

Comments (see below)

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Function 9. Check availability of fresh water. Fresh water supply pressure must be between 2-7 bars. Bleed air from fresh water pump and check rotation direction, if applicable 10. Check availability of seawater. 11. Check availability of air supply. Air supply pressure must be between 4-12 bars 12. Check that drain connection or equivalent is available on pump unit. 13. Check that flushing valves amount and position match the ones in drawings. 14. Check that all signs are on place. 15. Check availability of main and emergency power supply. 16. Visual inspection of the electrical termination within the pump unit control panel. Check that all cores are identified. 17. Visual inspection of all interconnection junction boxes. Check that all cores are identified. 18. Visual inspection of bridge panel installation. Check that all cores are identified. 19. Visual inspection of ECR panel installation. Check that all cores are identified. 20. Visual inspection of local release buttons and audible/visual alarms.

Completed

Comments (See below)

Engineer Comments: -

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

5. Notes:

System Start Up Procedures

The following procedure is based on the preferred order of equipment start up, taking into consideration the interface requirements between equipment and components. All functions are to be used in conjunction with the relevant commissioning engineer instruction manual. Where problems occur, deviations found, or where there is any doubt on the integrity of the component or installation being tested, Do Not Proceed until the problem has been rectified or repaired. If in doubt, STOP, and ask.
Function 1. Check that current condition of the system matches to the information given in system pre-commissioning list. 2. Close pump unit main outlet valve 3. Close all system isolation electrical switches including all pump main circuit breakers. 4. Remove all nitrogen and foam cylinder actuation solenoid connection plugs. 5. Switch on main incoming 3-phase power supply, up to the pump unit main isolator. Check and record the incoming voltage. Acceptable range for voltage is 10% to +15% from the nominal value. 6. Within the pump unit panel, switch on the main 3 phase/230 V power supply, check and record voltage out-put from mains transformer. Completed Comments (See below)

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Function 7. Switch on 230 V supply to 24 V DC power supplies, check and record DC voltage(maximum out-put 27,3 V DC at battery terminals) 8. Switch on all 230 V and 24V DC control circuit isolators and check for 24 V DC earth faults. 9. Check oil level and quality in all high-pressure pumps, top up as necessary. 10. With the fresh water break tank empty, check that the fresh water solenoid control valves are in the open position. 11. With the fresh water tank empty, check that the high-pressure pump isolation relay is activated. 12. Check that the automatic fresh water pump start signal is activated (Relay) if applicable 13. Open the fresh water supply and bleed the fresh water supply pump and all relevant inlet pipework and filter. 14. Switch on feed water pump. Check for correct rotation and that water flows unrestricted into the HI-FOG system break tank(s). 15. Check that the fresh water pump stops on break tank filling. 16. Close main outlet valve. Manually start each high-pressure pump unit in turn, checking that the maximum pressure of approximately 140 bar is reached. Reset after each start. 17. Open air supply to stand-by pump and re-set the system, adjust the stand-by pump to the appropriate stand-by pressure.

Completed

Comments (see below)

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Function 18. Check water trap reservoir on the stand-by pump regulator, empty if necessary. 19. Check lubrication reservoir and fill as necessary. 20. Check the condition of the break water inlet line filter element. Check also that by-pass valve located in the filter is closed. Bleed filter. 21. Adjust the pump unit flow switch. 22. Open ball valve on pump unit. Fill main line and check for leakage. 23. Fill each protected section by opening each relevant section valve in turn. Check for leakage. 24. Bleed each section by opening the flushing valve. Allow water to flow freely and verify that right section valve indicates. 25. Fill and bleed all water cylinders. 26. Check that all nitrogen valves are installed correctly. Open all cylinder valves and check for leakage. 27. Check all nitrogen cylinder pressures, check setting of all nitrogen cylinder pressure switches. 28. Check contents and foam level of the foam cylinder. 29. Re-set the system and check stand-by pump for stability. 30. Check feed water filter on pump unit. Engineer Comments: -

Completed

Comments (See below)

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

6.

Commissioning Tests. Once it has been established that the system and all components are fully operational and all pipework/cylinders have been filled and physically tested, the following commissioning tests should be carried out so as to verify full system operation against the original design.

Notes: These tests are to be carried out to the satisfaction of the commissioning engineer and are in addition to, and prior to, the forwarding of the system for third party acceptance, Where tests include system alarms, alarm activation must be checked both at the pump unit and the bridge panel.

Test 1. Earth fault alarm (24VDC) 2. Pump unit/system fault in bridge panel or equivalent ship system 3. Pump unit fault alarm in pump unit and bridge panel or equivalent ship system 4. Check that pressure gauges in all panels correspond to the system pressure 5. No fresh water alarm in pump unit and bridge panel or equivalent ship system 6. Automatic power transfer from main to emergency supply on main power isolation. 7. System reverts to main power on system re-instatement. 8. HI-FOG activated indication on bridge panel or equivalent ship system 9. Activation of each accommodation section alarm and fire alarm. For details see attachment 1. 10. Reset function from pump unit, remote activation panel(s) and bridge panel or equivalent ship system.

Completed

Comments (See below)

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Test 11. Foam cylinder solenoid activation on receipt of start up signal. (If applicable) 12. Machine space system activation from remote activation panel, fire detection system, local release buttons. For details see attachment 2. (If applicable) 13. Emergency start of all pumps from bridge panel or equivalent ship system and remote activation panel(s). (If applicable) 14. Automatic actuation of highpressure pumps on activated standby pump flow switch for 10 seconds. 15. Automatic activation of highpressure pumps from low pressure. 16. Automatic activation of nitrogen cylinder solenoid, on fire alarm signal with all pumps isolated. 17. Low nitrogen pressure alarm. 18. Deep Fat Fryer release. (If Applicable) 19. Test valve signals from cold room. (If applicable)

Completed

Comments (See below)

Engineer Comments: -

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

7.

Third Party Approval and Acceptance Tests On completion of all engineers commissioning tests the system must be demonstrated to the representative or inspector for the classification or test authority having jurisdiction over the vessel. Classification acceptance tests may include all or some of the commissioning tests and will be at the sole discretion of the representative of the relevant classification authority, all of which will have been previously documented, approved and agreed. For classification approval test requirements refer to the relevant documentation as detailed within the Hi-fog system operating and test manual.

Classification Authority: Classification Representative: Date of acceptance tests: Ship Representative:

Commissioning/test Engineer:

Acceptance Test Details: -

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Attachment 1. Commissioning test protocol for HI-FOG in accommodation areas


Broken wire alarm. Activation of HP-pump unit from section valve test connection and correct alarm verified on Bridge Panel or equivalent ship system. Correct signal to PLC-unit from each section valve verified.

Test of accommodation section valves and related functions. Test function:

Accommodation section valve S1 Accommodation section valve S2 Accommodation section valve S3 Accommodation section valve S4 Accommodation section valve S5 Accommodation section valve S6 Accommodation section valve S7 Accommodation section valve S8 Accommodation section valve S9 Accommodation section valve S10 Accommodation section valve S11 Accommodation section valve S12 Accommodation section valve S13 Accommodation section valve S14 Accommodation section valve S15 Accommodation section valve S16 Accommodation section valve S17 Accommodation section valve S18 Accommodation section valve S19 Accommodation section valve S20 Accommodation section valve S21 Accommodation section valve S22 Accommodation section valve S23 Accommodation section valve S24 Accommodation section valve S25 Accommodation section valve S26 Accommodation section valve S27 Accommodation section valve S28 Accommodation section valve S29 Accommodation section valve S30 Accommodation section valve S31

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Accommodation section valve S32 Accommodation section valve S33 Accommodation section valve S34 Accommodation section valve S35 Accommodation section valve S36 Accommodation section valve S37 Accommodation section valve S38 Accommodation section valve S39 Accommodation section valve S40 Accommodation section valve S41 Accommodation section valve S42 Accommodation section valve S43 Accommodation section valve S44 Accommodation section valve S45 Accommodation section valve S46 Accommodation section valve S47 Accommodation section valve S48 Accommodation section valve S49 Accommodation section valve S50 Accommodation section valve S51 Accommodation section valve S52 Accommodation section valve S53 Accommodation section valve S54 Accommodation section valve S55 Accommodation section valve S56 Accommodation section valve S57 Accommodation section valve S58 Accommodation section valve S59 Accommodation section valve S60 Accommodation section valve S61 Accommodation section valve S62 Accommodation section valve S63 Accommodation section valve S64 Accommodation section valve S65

Comments:

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Attachment 2. Commissioning test protocol for HI-FOG in Machinery Spaces


Activation of visual/audible alarm inside protected area on flow signal from section valve. Feed back from section valve flow switch (push button for section illuminated on ECR panel). Automatic release via fire detection system (needs 2 detectors in alarm at same time per section). Release from local push button (same procedure as above). Release from push button on remote activation panel(s) (activation of solenoid on section valve, connector plug

Test function:

Test of machinery section valves and related functions.

Machinery section valve M1 Machinery section valve M2 Machinery section valve M3 Machinery section valve M4 Machinery section valve M5 Machinery section valve M6 Machinery section valve M7 Machinery section valve M8 Machinery section valve M9 Machinery section valve M10 Machinery section valve M11 Machinery section valve M12 Machinery section valve M13 Machinery section valve M14 Machinery section valve M15 Machinery section valve M16 Machinery section valve M17 Machinery section valve M18 Machinery section valve M19 Machinery section valve M20 Machinery section valve M21 Machinery section valve M22 Machinery section valve M23 Machinery section valve M24 Machinery section valve M25 Machinery section valve M26 Machinery section valve M27 Machinery section valve M28 Machinery section valve M29 Machinery section valve M30

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05

Test of fire detection loops: Zone 1 Zone 2 Zone 3 Zone 11 Zone 21 Zone 12 Zone 22 Zone 13 Zone 23

Zone 4 Zone 14 Zone 24

Zone 5 Zone 15 Zone 25

Zone 6 Zone 16 Zone 26

Zone 7 Zone 17 Zone 27

Zone 8 Zone 18 Zone 28

Zone 9 Zone 19 Zone 29

Zone 10 Zone 20 Zone 30

Comments:

Commissioning Report HI-FOG SPU-Unit

FM040 Date: 12.10.05