2 1 AS BUILT 2012.01.

10 EDS ASK NTU

1 0 FIRST ISSUE 2010.05.10 EDS ASK NTU

SEQ REV CHANGES DATE DESIGNED CHECKED APPROVED

STATUS

AS BUILT
OBJECT

CHANGUINOLA I HYDROELECTRIC PROJECT

CONSORCIO GAVILAN

CHANGUINOLA CIVIL WORKS

JOINT VENTURE
DESIGN ENGINEERS

CHANGUINOLA I HPP
MINI HYDRO
DESIGNED BY CHECKED BY
POWER HOUSE - DETAILED DESIGN
E. SA A.KONICKI
APPROVED BY
OIL RECOVERY SYSTEM
N.UEMATSU COMMISSIONING INSTRUCTION
DATE SCALE FORMAT DOCUMENT NUMBER (MANUFACTURER) SHEET / OF

2010.05.10 - A4 1/10
DOCUMENT NUMBER – rev

HLA-CHA-03-GDB-DC-00-004-1
 Sheet 2 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

ACO ttm produkter

Tel: +46 31 338 97 03

Fax: +46 31 338 97 29
Mobil: +46 70 20 86 444

Web: www.aco-nordic.se
E-post: david.anderson@aco-nordic.se

ACO Nordic AB
Walckesgatan 1
415 02 Göteborg
Tel. 031-338 97 00
Fax 031-338 97 29
info@aco-nordic.se

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 3 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

CONTENT

FOREWORD
WARNINGS
DESCRIPTION
PRE-COMMISSIONING
COMMISSIONING
CONTRACT DRAWING LIST
EQUIPMENT COMMISSIONING DOCUMENTS
INSTALATION TEST CERTIFICATES

FOREWORD

The information contained in this Instruction Manual is intended for the interest and use of personnel
responsible for the safe and efficient installation of the equipment supplied by ACO Nordic.

This manual should be studied by plant personnel and be available for reference.

Commissioning Instructions Prepared By:

WARNINGS

(1) ACO Nordic and ALSTOM cannot accept responsibility for pipe fracture due to differential
settlement between pipe and building or building and building.

(2) Scaffolding, ladders or any other item of plant or equipment 'MUST NOT' be attached to or
supported from any part of the Water/Oil Separator system equipment.

(3) All electrical system equipment to be installed and maintained by competent persons in
accordance with Electrical Equipment of Buildings IEE Regulations and applicable site practices.

(4) UNDER NO CIRCUMSTANCES may any cable rack, steelwork, plant or equipment be used as a
temporary workbench or as a means of access
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 4 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

(5) All reasonable precautions will be taken to protect items of plant from physical damage and ensure
personnel safety from the items of equipment during the installation period.

All personnel working under this installation instruction manual must be conversant with the Site
Safety Rules and Procedures.

The nominated erection team will be issued with all the necessary personal safety equipment, and
will be instructed on the procedures to be adopted to deal with accidents, and incidents

Site supervision will be constant to monitor the work in progress and maintain a high standard of
Good Housekeeping.

Toxic fumes may be created in a separator never enter into a separator without a fresh air
inlet mask, life line and assistance

(6) The quality of the drainage should meet Panamanian legal requirements for sewage water
drainage. (Copanit 35-2000).

The oil separators is designed to maintain a 5-ppm maximum oil-in-water effluent

The sampling collect procedure, should meet Panamanian legal requirements referring to the
number of samples, volume, labeling, conditioning and transport to the Laboratory

Description

The Drainage and Oil Recovery System for the Mini Hydro Powerhouse consist, on the connection of the
drainage oil system of the powerhouse and the drainage of the transformer bay to a pre-fabricated oil
separator device, filtering any spill that can pollute the Changuinola River through the discharge station
sump.
The water and oil from the drainage system coming from the drainage sump is routed to the flow regulator
sump, before the Oil Separator Unit entrance using cast iron soil pipes interconnecting. A flow regulator is
installed at the inlet flow in the separator to control the inflow in case a major spill occur (up to 4000 litters
approximated) that can overflow the capacity of the Oil Separator Unit.
The separator has an automatic level detector, which will give an overflow warning if the quantity of oil
exceeds the oil storage volume.
The alarm will send the signal to main panel board in the control room of the main powerhouse monitoring
the quality of the water flowing through the device.
Any oil leakage from transformers oil tank seepage or rupture will be routed to the same separator and an
automatic shut-off valve will be use to isolate the separator in case of the presence of a high oil level
signal at the Alarm module that will send the signal to main panel board too. The transformer pit will
contain the water and oil
The Oil Separator Unit operates with the gravity principle combined with an integrated coalesce. Sludge
and heavier particles separate and fall down to the bottom of the tank, while the oil, being lighter than the
water, rises to the surface. Small oil particles with a low rising velocity are trapped in the filter by the
coalescence effect to bigger drops, which are easy to separate.

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 5 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

The oil separator unit is designed to maintain a 5ppm maximum release hydrocarbons to a natural stream
according local regulation.
A sampling unit is provided for quality purposes at the oil separator outlet pipe, where water samples can
be take for maintenances analysis.
During maintenance period manual shut-off valve has installed at the outlet pipe to isolate the drainage
lines coming form the pit transformer. Incoming drainage from the Power House can be isolate at the pup
station. The Oil water Separator system scope include the items described below:

One (1) Oil / Water Separator Miri OAM 41 20 S

One (1) Level and Alarm panel Miri Alarm
One (1) Oil sampler well Miri PBM 200
One (1) Flow Regulator Mosbaek
One (1) Inlet manual valve
One (1) Inlet automatic valve
One (1) discharge check valve

When carrying out routine test and maintenance procedures on the fire protection system equipment care
must be taken in order to prevent the inadvertent operation of system equipment

Pre-Commissioning Procedures

Refer to latest contract drawings when performing Water/Oil Separator and commissioning test procedures.

Confirm that all equipments complies with the contract drawings in all aspects that are relevant to the safe
and effective operation of the system

“All Pre-commissioning General Inspection Checks Complete” comprise:

-Visual workmanlike
-Dimensional accuracy
-Project according
-Properly and safe installation
-Maintenance accessibility
-Label and advise located in the normal field vision
-Water, air compressed and fire suppression availability
-Piping well fixed and stabilized
-Water resistant sealing where apply
-Manual, automatic and check valves operating correctly
-Panel electrical terminals tight
-Equipment properly grounding
-Motors isolation test done
-Electrical wire continuity test done

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 6 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

Commissioning Procedures

MIRI OAM 41 / 20S OIL SEPARATOR COMMISSIONING TEST RECORD SHEET

CLIENT ALSTOM ACO

ITEM EQUIPMENT
Initial Initial Initial
1 General Inspection BLANK BLANK BLANK
1.1 All Pre-commissioning General Inspection Checks
Complete
2 Commissioning Test Procedure BLANK BLANK BLANK
2.1 Open the cover and remove out of the separator the
automatic shut off valve or lift up from its seat to prevent
blocking
2.2 Fill with water the flow regulator sump to the outlet level
of the separator looking the tailrace check valve exit flow
For next procedure related refer to the Operation & BLANK BLANK BLANK
Maintenance Manual
2.3 The sensor for thick oil level reach 150 mm
2.4 The sensor damming mounted 100 mm above the
separator’s inlet piping
2.5 Automatic shut off valve is correctly adjusted and free
floating
2.6 Lift the oil level sensor out of the water the alarm shall
release and give light and sound .Put the sensor back
into the water. Light and sound signals will stop
2.7 Lower the damming sensor into the water. The alarm
shall release and give light and sound signals. Lift the
sensor out of the water. Light and sound will stop

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

FLOW REGULATOR CEV OIL SEPARATOR COMMISSIONING TEST RECORD SHEET

ITEM EQUIPMENT CLIENT ALSTOM ACO
Initial Initial Initial
1 General Inspection BLANK BLANK BLANK
1.1 All Pre-commissioning General Inspection Checks
Complete
2 Commissioning Test Procedure BLANK BLANK BLANK
2.1 Check it’s unclogging and sump clean
2.2 The flow regulator is a wedge coupling and rod lifting
with adjustment plate. Adjustment plate in the mean

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 7 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

position the inlet opening may be adjusted ± 20% of

the capacity. Adjust required 20l/s

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

MIRI ALARM DUO 20 TYPE4 COMMISSIONING TEST RECORD SHEET

ITEM EQUIPMENT CLIENT ALSTOM ACO

Initial Initial Initial
1 General Inspection BLANK BLANK BLANK
1.1 All Pre-commissioning General Inspection Checks
Complete
2 Commissioning Test Procedure BLANK BLANK BLANK
2.1 Lifting and lowering the oil sensor verify the realize and
stop of light and sound

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

SAMPLING WELL MIRI PBM 200 COMMISSIONING TEST RECORD SHEET

ITEM EQUIPMENT CLIENT ALSTOM ACO
Initial Initial Initial
1 General Inspection BLANK BLANK BLANK
1.1 All Pre-commissioning General Inspection Checks
Complete

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 8 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

COVER MIRI NIC 700 COMMISSIONING TEST RECORD SHEET

ITEM EQUIPMENT CLIENT ALSTOM ACO
Initial Initial Initial
1 General Inspection BLANK BLANK BLANK
1.1 All Pre-commissioning General Inspection Checks
Complete

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

EXIT CHECK VALVE COMMISSIONING TEST RECORD SHEET

ITEM EQUIPMENT CLIENT ALSTOM ACO
Initial Initial Initial
1 General Inspection BLANK BLANK BLANK
1.1 All Pre-commissioning General Inspection Checks
Complete

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

AUTOMATIC BUTTERFLY VALVE COMMISSIONING TEST RECORD SHEET

ITEM EQUIPMENT CLIENT ALSTOM ACO

Initial Initial Initial
1 General Inspection BLANK BLANK BLANK
1.1 All Pre-commissioning General Inspection Checks
Complete
2 Commissioning Test Procedure BLANK BLANK BLANK
2.1 Lift the oil level sensor out of the water the alarm shall
release and give light and sound. The automatic butterfly
valve shall close. Put he sensor back into the water. Light
and sound signals will stop. The automatic butterfly valve
shall open

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 9 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

MANUAL BUTTERFLY VALVE COMMISSIONING TEST RECORD SHEET

ITEM EQUIPMENT CLIENT ALSTOM ACO

Initial Initial Initial
1 General Inspection
1.1 All Pre-commissioning General Inspection Checks
Complete

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

EFFLUENT SAMPLE

ITEM SAMPLE CLIENT ALSTOM ACO

Initial Initial Initial
1 General Inspection
1.1 Oil/Water sample
1.2 Oil/Water sample
1.3 Oil/Water sample

CLIENT Witness Signature.

ALSTOM Witness Signature.
ACO Witness Signature.
Date

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden
 Sheet 10 of 10
CHANGUINOLA I Date 2010.05.10
Doc Nr. HLA-CHA-03-GDB-DC-00-004-1

DRAINAGE AND OIL RECOVERY SYSTEM –COMMISSIONING INSTRUCTION

REFERENCES
[1]
HLA-CHA-03-GDB-FB-00-003 - MINI HYDRO - POWER HOUSE - DETAILED DESIGN - OIL
RECOVERY SYSTEM - PIPING INSTRUMENT DIAGRAM
[2]
HLA-CHA-03-GDB-LD-00-001 - MINI HYDRO - POWER HOUSE - DETAILED DESIGN - OIL
RECOVERY SYSTEM - INSTALATION DRAWING
[3]
HLA-CHA-03-GDB-LD-00-002 - MINI HYDRO - POWER HOUSE - DETAILED DESIGN - OIL
RECOVERY SYSTEM - DETAILED DRAWING
[4]
HLA-CHA-03-GDB-LD-00-003 - MINI HYDRO - POWER HOUSE - DETAILED DESIGN - OIL
RECOVERY SYSTEM – EMBEDDED PIPINGS DRAWING
[5]
HLA-CHA-03-GDB-PA-00-001 - MINI HYDRO - POWER HOUSE - DETAILED DESIGN - OIL
RECOVERY SYSTEM - MATERIAL LIST
[6]
HLA-CHA-03-GDB-DD-00-001 - MINI HYDRO - POWER HOUSE DETAILED DESIGN - OIL
RECOVERY SYSTEM - CALCULATION REPORT

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden