Test Method - ACT Tester-Rev.8

METHOD STATEMENT GUIDELINE
ITEM: RE-COMMISSIONING OF AIR COMPRESSOR TESTER (20.1201)
Construction of Mass Rapid Transit Jakarta

Contract Package CP101
Contents
1. General..............................................................................................................................................2
1.1 Automatic operation....................................................................................................................2
1.2 Manual operation........................................................................................................................2
1.3 Initial Check.................................................................................................................................2
1.4 Work Procedure...........................................................................................................................5
2. Test Procedure................................................................................................................................7
2.1 Procedure....................................................................................................................................7
2.2 Each Test Item...........................................................................................................................11
2.2.1 Preliminary test..................................................................................................................11
2.2.2 Load temperature rise test................................................................................................12
2.2.3 Oil Temperature Control Valve operation..........................................................................15
2.2.4 Leakage test.......................................................................................................................17
2.2.5 Test to check the pressure loss (air compressor portion)..................................................19
2.2.6 Volumetric efficiency check test........................................................................................21
2.2.7 Minimum pressure valve open/close.................................................................................22
2.2.8 Minimum Pressure Valve Setting Pressure........................................................................24
2.2.9 Minimum Pressure Valve Operation..................................................................................26
2.2.10 Safety Valve blowing off.....................................................................................................28
2.2.11 Insulation Resistance test..................................................................................................30
2.2.12 Withstanding Voltage test.................................................................................................31
2.2.13 Air dryer unit test...............................................................................................................32
3. Checklist.........................................................................................................................................38
1
1. General
This equipment is both capable of remote-mode (as automatic operation) and local-mode
(as manual operation) in which all of the processes are involved in. Especially in manual
operation, the operator has to pay extra caution to the working circumstances in order to
prevent any accidents.
1.1 Automatic operation

When operated automatically, PLC program and enables automatic operation by running
and stopping the equipment in serial order.
 Check all the circuit breakers are on.
 Connect the canon to be tested.
 Turn on the main power S/W.
 Turn on the Industrial computer
 Turn on the insulation resistance withstanding voltage tester
 Set Remote/Local S/W to automatic
1.2 Manual operation

 Check all the circuit breakers are on.
 Connect the canon to be tested.
 Turn on the main power S/W.
 Turn on the Industrial computer
 Turn on the insulation resistance withstanding voltage tester
 Set Remote/Local S/W to manual.
1.3 Initial Check

Items to be checked during the first operation of the air compressor.
2
Pressure Gauge1 (Oil Recovery Unit)
Pressure Gauge2 (tank 10L)
3
- Pneumatic schematic figure between AC and Tester & ACT system diagram
4
- Press the ON switch on the ac 380v power control.

- Press the start switch of the Inverter and press the stop button after 1-2 seconds.
- When start switch is pressed, the direction of rotation should be checked when the motor
rotatesin the air compressor.
- If you look at the air compressor, there is a rotation direction indicator.
* If it is not normal, two of the power lines of the air compressor must be crossed and
connected.
1.4 Work Procedure
•Load a compressor on the test bench
•Check Assembled condition, Oil Level.
•Set up test preparation of the air compressor.

1. Connect the main power of the compressor to inverter of tester.
2. Connect the air outlet of the compressor to air tank of tester.
3. Install the speed sensor, turn on the pressure gauge, temperature sensor.
↓
•Set air compressor tester to test ready.
5
1. Turn on the main power and turn on the computer.
2. Execute the air compressor tester executable file.
•Select the test method from the menu of program.

1. Preparatory test (No load running test).
2. Remote mode.
Among 13 items, only 3 test items are automatic operation and others are manual
operation.
<3 test items : automatic>
- Volumetric efficiency check test
- Insulation test
- Withstanding voltage test.
<other 10 test items : manual>
- Air dryer unit test, preliminary test, Minimum pressure valve open/close, Minimum
Pressure Valve Setting Pressure, Minimum Pressure Valve Operation, Test to check the
pressure loss, Leakage test, Load temperature rise test, Safety Valve blowing_off, Oil
Temperature Control Valve operation,
3. Local mode.
If there are any failed test items in the remote mode test
Select and retest.
↓
•If all the tests are successful after checking the test report, remove
the air compressor from the test bench.
↓
•Transfer Compressor.
6
2. Test Procedure
2.1 Procedure
1) Open the program of Air Compressor tester.
2) Click the OK button on the main screen password entry screen to move on.
3) Enter the password and click the OK button to go to the menu screen.
4) Click the Start Test button on the menu screen to move on to the test screen.
7
5) Enter the inspection information for the object to be tested.
6) Enter the inspection information for the object to be tested. When the test item appears,
check the item you want to test.(If you check the automatic test, all items will be checked.)
7) Click the button to start the test.
8
8) Save report, go to the Test report review
9) Click tab “File”, Click “Save Report” and click OK
9
10) Back to the test screen, Click tab “Test Screen” and choose “test screen”
11) The screen will be back to the test screen. Choose other item of test and start the other
item test.
Notes:
 Item test check one by one item, after finish the test, input the value to the program
of air compressor tester and save the report directly in the pop up dialogue.
10
2.2 Each Test Item

2.2.1 Preliminary test
Teflon Hose
Gauze
1) Remove the Teflon hose from the aftercooler outlet, attached the new gauze and
locked it with clamp ring.
2) Take a photo of the gauze before condition.
3) Turn the Volume in the Speed Control section clockwise.

4) Press the ON switch on the AC 380V POWER CONTROL.
5) Press the start switch on the Inverter (The motor operates.)
6) Each part shall be free from oil leakage and air leakage.
7) Visible oil drops shall not be discharged from the discharge port.
8) Put a piece of gauze in a position approx. 5 cm from the discharge port (from
aftercooler outlet) (for 5 minutes) and the gauze shall be free from discoloration (yellow)
due to oil.
9) After completion, press the stop switch on the INVERTER.
10) Press the OFF switch on the AC 380V POWER CONTROL.
11) Take a photo of the gauze after condition for documentation.
11
2.2.2 Load temperature rise test

1) Prepare the record table
Time AT AET MT OT A R
(°C) (°C) (°C) (°C) (ampere)
0s
600 s
1200 s
1800 s
Notes:
AT: Ambient Temperature OT: Oil temperature
AET: Air End Temperature A: current phase (ampere)
MT: Motor temperature r: Resistance cable power
2) Measure and record the temperature of the power cable of the air compressor. (t₁)
3) Measure and record the resistance between the phases of the power cable of the air
compressor (R₁). Measure the resistance before running the compressor. The power
should be in off condition and the air compressor should be in the cold condition.
4) Measure and record the ambient temperature.
5) Disconnect the pipe from the aftercooler outlet.
12
6) Connect the tester hose to the aftercooler outlet.

7) Close valves 5, 6, 8 and 9.
8) Open valve 7.
9) Turn on the MV3, MV4 switches (around 200-400 kPa).

10) Turn the volume on the pneumatic control clockwise or counterclockwise so that the load
pressure adjustment value reads 885 kPa.
13
11) Turn the volume in the speed control section clockwise to the maximum.
13) Press the start switch on the Inverter.
14) Measure and record temperature every 10 minutes intervals for 30minutes (0,10,20,30
min.). Record it and write it on the record table which already prepare.
15) Measure and record the ampere meter every 10 minutes intervals in 10 minutes, 20 minutes
and 30 minutes
16) Press the OFF switch on the AC 380V POWER CONTROL after completion for 30 minutes.
17) Measure and record the resistance between the phases of the power cable of the air
compressor (R₂). Compressor should be in the stop operation condition.
18) Turn on the MV1, MV2 switches.

19) Wait until all the pressure in the LOAD tank is exhausted.
20) Turn off the MV1, MV2, MV3, MV4 switches.
Notes:
 In the operation of the Load temperature rises, it including check test item for:
a. [2.2.3] Oil temperature control valve (need check after 30 minutes operation)
b. [2.2.4] Leakage test (need check after 30 minutes operation, check each part while
operating)
14
2.2.3 Oil Temperature Control Valve operation

3) Close ball valves 5, 6, 8 and 9.
4) Open ball valve 7.
15
5) Attach the temperature sensor.

10) Turn on the MV4 switches (when it around 200 – 400 kPa) and MV3 switches.
11) Measure the maximum temperature of the oil filter during operation in 30 minutes. (88 ±
10℃)

16
2.2.4 Leakage test

4) Open valve 7.
17
10) Check each part for oil leaks and air leaks while operating for 30 minutes.
11) There should be no oil leakage or air leakage in each part.

18
2.2.5 Test to check the pressure loss (air compressor portion)

4) Open valve 7.
19
6) Turn on the MV3 and MV4 switches.
10) Check pressure in Load tank goes up to 885kPa under air compressor operating.
11) Check pressure in Oil recovery unit (see gauge1) goes up to 950kPa or less and does
not increase anymore.
20

15) Wait until both the LOAD tank and the Measuring Tank are exhausted.
16) Turn off the MV1, MV2, MV3, MV4 switches
2.2.6 Volumetric efficiency check test

4) Open valve 7.
5) Take a written record and photo to record the timer in the Discharge Air test and the
temperature in the panel of the air compressor tester.
21
6) In the discharge air test, turn on the test start switch.

7) Tests start and end automatically.
8) When the test is complete, the result is displayed on the indicator.
[test method]
a. With the load pressure, the pressure of the load tank is maintained at 885kPa.
b. And measure the time until the pressure of the measuring tank rises from 0 to 785 kPa.
c. Volumetric efficiency calculations should refer to Rail car manual.
2.2.7 Minimum pressure valve open/close
22

4) Open valve 7.

8) After 10 sec Check pressure in Oil recovery unit (see gauge1) is 390kPa or more.
(Minimum pressure valve closing and no leakage)
9) After 20 sec., Check pressure in Oil recovery unit (see gauge1) is 570kPa or less
(Minimum pressure valve opening) and Confirm Safety valve is not working.
23

14) Turn off the MV1, MV2 switches.
2.2.8 Minimum Pressure Valve Setting Pressure
24

4) Open valve 6.

Pressure Gauge2 (tank 10L)
8) Check pressure gauge2 (tank 10L) and check the gauge connected to the oil recovery device
(gauge 1) when the pressure rises.
9) The pressure of the gauge connected to the oil recovery device (gauge1) must be over 430
kPa.
25

2.2.9 Minimum Pressure Valve Operation.

4) Open valve 7.
26
8) Turn Volume clockwise on Pneumatic Control. At this time, set the Load pressure Adjustment
Value to be 685 kPa.
9) When the pressure in the load tank reaches 685kPa, press the stop switch on the Inverter.
10) At this time, check the gauge connected to the oil recovery device.
11) The pressure on the gauge must be 600kPa or higher. (5-1)
12) Press the MV1, MV2 switches. At this time, check the gauge connected to the oil recovery
device (gauge1) and check the exhaust time from 395kPa to 195kPa.
13) The exhaust time is between 40 and 70 seconds. (5-2)
27
2.2.10 Safety Valve blowing off

4) Open valve 6.
28
* If the motion is too fast, turn the volume in the speed control section counterclockwise to
adjust the speed.
8) Check the gauge connected to the oil recovery device (gauge1).
9) When the safety valve operates on the air compressor, the pressure of the gauge drops
momentarily.
10) Measure pressure before descending (valve open) and start increasing (valve close).
“Opening : 1110~1130 kPa” and “Close : 750kPa or more”
11) Push the button for the indicator Lamp when you hear the opening pressure. The other
operator record the video to check the value pressure when the map is on.
12) Then record until got the value of the pressure drop maximum before rises again is shown in
the gauge1 to check the close pressure.

29
15) Open valve 9 for air discharge.

16) Close valve 9.
2.2.11 Insulation Resistance test
1) Disconnect the power cord before testing.

2) Connect the cable prepared for insulation resistance test to power and ground.
30
3) After selecting the insulation resistance item in step 1, click the start button in step 2 to
proceed with the test.
4) Reconfirm the condition when the pop-up message is appeared, and click OK if all condition
is confirmed.
5) The result will save in the report
2.2.12 Withstanding Voltage test
1) Disconnect the power cord before testing.

2) Connect the cable prepared for withstand voltage test to power and ground.
31
3) After selecting the withstand voltage test item in step 1, click the start button in step 2 to
proceed with the test.
4) Reconfirm the condition when the pop-up message is appeared, and click OK if all condition
is confirmed.
5) The result will save in the report
2.2.13 Air dryer unit test
1) Connect the tester hose to the Air dryer unit outlet.
32
2) Disconnect Air return pipe and Install a plug on 3/8 elbow.
3) Close valves 5, 7, 8, 9.
4) Open valve 6.
33
1) Leakage test.
4) Fill the in 10L tank up to 785kPa ±3 kPa. (with RPM around 800, in pressure higher
between 790 - 800 kPa, and press stop)
5) Press the stop switch on the Inverter.
7) When the pressure has stabilized, record the pressure (See the gauge1).
8) Record the pressure after 1 minute.
9) Confirm pressure drop is not more than 7.5kPa
11) Close valve 9
34
2) Operation test of 2-port automatic drain valve.
1) The condition is same with the leaked test. Open valve 6, Close valve 5,7,8,9.
Ensure both of the pressure gauge in 0 value condition.
5) Check the lower part of the air dryer unit by hand.
6) If you feel air in your hand, push the button of the lamp indicator and record the
pressure gauge of the 10L tank (gauge2).
7) Up to 180kPa +/- 30kPa, drain valve opens and air discharge
8) When air is continuously felt but no air is felt, push the button of the lamp indicator
and record the pressure gauge of the 10L tank (gauge2).
9) At 300kPa +/- 30kPa, valve closes and no discharge.
35

12) Close valve 9.
3) Air flow volume test
1) Remove the plug on air return pipe, and Connect return pipe.
2) Close valve 6
36
Pressure Gauge2 (10L tank)
5) See the oil recovery gauge, when it shown over 600 kPa, open valve 6.
6) Measure the time from 0 to 685 kPa. (8sec or less)
8) Press the OFF switch on the AC 380V POWER CONTROL
9) Check the pressure gauge of the oil recovery (gauge1).
10) Measure the time from 685kPa to 390kPa.(8.8 ± 3sec)

12) Close valve 9
13) end of the test.
37
3. Checklist
38
39
Attachment. Standard Value of Air Compressor Tester

No Item Standard Value
1 Air Dryer Unit 　
- 1.1 Leakage Test 7.5 kPa or less in 1 minutes
Operation Test of 2 port automatic Opening pressure: 180 ±30 kPa
- 1.2
drain valve Closing Pressure: 300 ±30 kPa
Check Valve: from 0 to 685 kPa Spec 8.0 s or less
- 1.3 Air flow Volume Test
Purge air choke: 685 to 390 kPa spec: 8.8 ±3.0 s
Put a piece of gauze 5 cm from discharge port (aftercooler outlet)
2 Preliminary test
the gauze shall be free from discoloration (yellow) due to oil
The pressure in the oil recovery unit is more than 390 kPa ,
Spec: at 10 s after start up
Minimum Pressure valve
3 The pressure in the oil recovery unit is less than 570 kPa or the
open/close
safety valve has blown off air,
Spec: at 20 s after start up
Minimum Pressure valve setting
4 Spec: Pressure in the oil recovery unit 430 kPa or more.
pressure
Supply the pressure air to the load air reservoir and up to 685 kPa
and stop the air compressor.
Minimum Pressure valve Spec: The pressure of the oil recovery unit is 600 kpa or more
5
operation Discharge until the pressure in the oil recovery decreases from 395
to 195 kPa
Spec: within 40 to 70s

6 Pressure loss Pressure in the oil recovery unit 950 kPa or less
Continuously 30 minutes under a load pressure goes up to 885 kPa
7 Leakage Test
Spec: each part shall be free from oil leakage and air leakage
Spec: Discharge port ambient temperature +10°C
8 Load temperature Rise
Electric wire of motor stator 140K
Spec:
9 Safety Valve Blowing-off open 1110 to 1130 kPa
Close 750 kPa or more
Oil Temperature control valve
10 Spec: maximum value of surface temperature oil filter 88 ±10°C
operation
Load air reservoir : 885kPa
11 Volumetric efficiency Measurement air reservoir : 0 → 785 kPa
Spec: 561.0 Nl/min or more
12 Insulation Resistance Spec: more than 10 MΩ
There should be no electric discharge sound.
13 Withstanding voltage test
[This sound is the sign of dielectric breakdown (short circuit).]
40

Test Method - ACT Tester-Rev.8

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Test Method - ACT Tester-Rev.8

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METHOD STATEMENT GUIDELINE

ITEM: RE-COMMISSIONING OF AIR COMPRESSOR TESTER (20.1201)

Construction of Mass Rapid Transit Jakarta

1.1 Automatic operation

1.2 Manual operation

1.3 Initial Check

Pressure Gauge1 (Oil Recovery Unit)

Pressure Gauge2 (tank 10L)

- Press the ON switch on the ac 380v power control.

1.4 Work Procedure

•Load a compressor on the test bench

•Check Assembled condition, Oil Level.

•Set up test preparation of the air compressor.

2. Connect the air outlet of the compressor to air tank of tester.

1. Turn on the main power and turn on the computer.

2. Execute the air compressor tester executable file.

•Select the test method from the menu of program.

5) Enter the inspection information for the object to be tested.

7) Click the button to start the test.

8) Save report, go to the Test report review

9) Click tab “File”, Click “Save Report” and click OK

2.2 Each Test Item

3) Turn the Volume in the Speed Control section clockwise.

2.2.2 Load temperature rise test

5) Disconnect the pipe from the aftercooler outlet.

6) Connect the tester hose to the aftercooler outlet.

9) Turn on the MV3, MV4 switches (around 200-400 kPa).

18) Turn on the MV1, MV2 switches.

2.2.3 Oil Temperature Control Valve operation

1) Disconnect the pipe from the aftercooler outlet.

2) Connect the tester hose to the aftercooler outlet.

5) Attach the temperature sensor.

8) Press the ON switch on the AC 380V POWER CONTROL.

14) Turn on the MV1, MV2 switches.

2.2.4 Leakage test

1) Disconnect the pipe from the aftercooler outlet.

2) Connect the tester hose to the aftercooler outlet.

5) Turn on the MV3, MV4 switches.

14) Turn on the MV1, MV2 switches.

2.2.5 Test to check the pressure loss (air compressor portion)

1) Disconnect the pipe from the aftercooler outlet.

2) Connect the tester hose to the aftercooler outlet.

14) Turn on the MV1, MV2 switches.

2.2.6 Volumetric efficiency check test

1) Disconnect the pipe from the aftercooler outlet.

2) Connect the tester hose to the aftercooler outlet.

6) In the discharge air test, turn on the test start switch.

2.2.7 Minimum pressure valve open/close

1) Disconnect the pipe from the aftercooler outlet.

2) Connect the tester hose to the aftercooler outlet.

5) Turn the Volume in the Speed Control section clockwise.

12) Turn on the MV1, MV2 switches.

2.2.8 Minimum Pressure Valve Setting Pressure

1) Disconnect the pipe from the aftercooler outlet.

2) Connect the tester hose to the aftercooler outlet.

5) Turn the Volume in the Speed Control section clockwise.

Pressure Gauge1 (Oil Recovery Unit)

Pressure Gauge2 (tank 10L)

11) Press the OFF switch on the AC 380V POWER CONTROL.

2.2.9 Minimum Pressure Valve Operation.

1) Disconnect the pipe from the aftercooler outlet.

2) Connect the tester hose to the aftercooler outlet.

2.2.10 Safety Valve blowing off