Code-01

Contract No. MEW/C/5504-2020/2021

Contractor HOT ENGINEERING AND CONSTRUCTION COMPANY Page 1 of 14
Client MINISTRY OF ELECTRICITY & WATER

DOCUMENT TITLE:

FUNCTIONAL TEST PROCEDURE FOR FIRE

AND GAS DEVICES
Document Number: P5504MEW-SWK-10-SS-V-PPR-001

Document approved with minor comment.

Refer markup comment on page 6 of 14.

PROJECT TITLE:

PROCUREMENT, CONSTRUCTION, COMMISSIONING AND MAINTENANCE FOR

UPGRADATION OF FUEL SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

Issued for Review /

A 26.Oct.2022 RN JV LTK JRM
Approval
PREPARED APPROVED CHECKED APPROVED
REV. DATE DESCRIPTION
SSS HOTECC
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES
Rev. No. : A
PROCUREMENT, CONSTRUCTION, COMMISSIONING
AND MAINTENANCE FOR UPGRADATION OF FUEL Page 2 of 14
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

REVISION LOG

REV REV. DATE REVISED PAGE REVISION DESCRIPTION

A 26.Oct.2022 - Issued for Review/Approval

 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES
Rev. No. : A
PROCUREMENT, CONSTRUCTION, COMMISSIONING
AND MAINTENANCE FOR UPGRADATION OF FUEL Page 3 of 14
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

INDEX

SL.No INDEX
CONTENT
PAGE NO.
1. INTRODUCTION 04
1.1 PURPOSE 04
1.2 SCOPE 04
2. DEFINITION AND ABBREVATIONS 04
2.1 DEFINITIONS 04
2.2 ABBREVATIONS 04
3. CODES & STANADRDS 05
4. REFERENCE 05
5. DESCRIPTION 05
6. LIST OF EQUIPMENT 06
7. TEST EQUIPMENT 07
8. FACTORY ACCEPTANCE TEST PROCEDURE 07
8.1 DOCUMENT VERIFICATION 07
8.2 MATERIAL INSPECTION 08
8.3 CALIBRATION TEST CHECKLIST FOR GAS DETECTORS 08
8.4 SIMULATION TEST CHECKLIST FOR FLAME DETECTORS 08
9. FAT CHECKLIST 09
9.1 MATERIAL INSPECTION CHEKLIST 09
9.2 CALIBRATION TEST CHECKLIST FOR GAS DETECTORS 10
9.3 SIMULATION TEST CHECKLIST FOR FLAME DETECTORS 11
APPENDIX – A TEST ATTENDANCE ROSTER 12
APPENDIX – B FACTORY ACCEPTANCE TEST (FAT) CERTIFICATE 13
APPENDIX – C PUNCH LIST 14
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES
Rev. No. : A
PROCUREMENT, CONSTRUCTION, COMMISSIONING
AND MAINTENANCE FOR UPGRADATION OF FUEL Page 4 of 14
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

1. INTRODUCTION

1.1. Purpose

This documented procedure has been established to ensure that all required tests and
inspections are carried out and documented for the acceptance of the Fire and Gas devices.

1.2. Scope

The scope of this document describes the inspection test procedures to be carried out prior
to the delivery at site for ensuring that the supplied Fire and Gas devices for the SHUWAIK POWER
STATION CONTROL BUILDING are in compliance with the project requirements and
specifications.

2. DEFINITION AND ABBREVIATIONS

2.1 Definitions

Company Ministry of Electricity & Water Authority (MEW)

Contractor HOT Engineering & Construction Co. (HOTECC)

Vendor Specialised Security Systems Co. (SSS)

Manufacturer Drager Safety, Germany (Gas Detectors, UV/IR Detectors)

MEDC, UK (Manual Call Points, Sounders and beacons)

2.2 Abbreviations

F&G - Fire & Gas

GD - Gas Detectors
MCP - Manual Call Point
LED - Light Emitting Diode
IO - Input Output
Ex. Proof - Explosion Proof
EN - European Standard
UL - Underwriters' Laboratories
TPI - Third Party Inspector
FAT - Factory Acceptance Test
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 5 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

3. Codes & Standards

BS EN 54 British standard for components of automatic fire detection systems

BS 5839 British standard for fire detection and alarm systems for buildings

NFPA 70 National electrical code

NFPA 72 National Fire Alarm Code

4. References

S.no Document Number Document Title

1. P5504MEW-SWK-10-SS-V-ITP-001 Inspection & Test Plan for Fire and Gas Devices

2. P5504MEW-SWK-10-SS-V-DAT-001 Vendor Datasheet for Fire and Gas Devices

3. P5504MEW-SWK-10-SS-V-MTO-001 Bill Of Material for Fire and Gas Devices

4. - Factory Test reports & Certificates

5. Description

The Inspection for the Fire and Gas devices shall be performed by the Manufacturer/ vendor
and witnessed by the representatives for Manufacturer/ vendor, HOTECC and MEW.

The Factory Acceptance test will be attended by representatives of the following:

Company/ TPI Ministry of Electricity and Water Authority (MEW)/ Third Party Inspector

Contractor/ TPI HOT Engineering Construction CO.(HOTECC)/ Third Party Inspector

Vendor Specialised Security Systems Co. (SSS), Kuwait

Manufacturer Drager Safety, Germany

Representatives/ attendees of all parties shall sign the test attendance rooster (Appendix A)
for record purpose.

FAT for the devices included in Table 1(Refer section 6) shall be conducted at the Manufacturer’s
Premises/ workshop in Germany prior to shipping to site location.

FAT Location;
Dräger Safety AG & Co. KGaA,
Lübeck, Germany
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 6 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

The FAT activities for the F&G devices involves.

• Document Verification
• Material Inspection.
• Calibration test for the Gas detectors.
• Simulation test for UV/IR Detector.

Material Inspection shall be caried out for the items mentioned in Table1 (Refer Section 6) and
recorded in the FAT Checklist (Refer Section 9.1). Calibration test for the gas detectors and Simulation
test for flame detector (UV/IR) will be carried out as per the FAT procedure (Refer section 9) and
recorded in the FAT Checklist (Refer section 9.2 and 9.3).

On successful completion of a test, the checklist sheet shall be marked as COMPLETED and
signed by the authorized representatives for Manufacturer/ Vendor, HOTECC and MEW. Upon
successful completion of all test’s, the authorized representatives for manufacturer/Vendor, HOTECC
and MEW shall sign the FAT ACCEPTANCE CERTIFICATE (Refer Appendix B). Subsequently,
IRN shall be issued by the Contractor/ TPI for shipment of the inspected items to site location.

During the activity, any non-compliance points shall be noted as punch points in the punch List
(Appendix C), and shall be attached with the FAT check lists for complete record of observation.
Based on the comments in the punch list, manufacturer/ vendor shall comply/ rectify the same. The
clearance of punch list shall be verified and signed off of the closure by HOTECC and MEW
representatives.

6. List of Equipment

Factory Acceptance Test shall be carried out for the below listed items.

Table 1 - Equipment List for FAT

Sl.
Item Description Model Manufacturer Total Qty (Nos)
No.
Polytron 8100 EC /
1. Toxic Gas Detector Drager Safety 29
8344412
Flammable (IR Point) Gas Polytron 8700 IR /
2. Drager Safety 27
Detector 8344610
Polytron 8200
3. Hydrogen Gas Detector Drager Safety 02
CAT / 8344448

Flame 2350 UV/IR

4. Flame Detector (UV/IR) Drager Safety 20
/ 6813926

Duct mounted Toxic Gas Detector (3 nos) and

Flammable Gas Detector (3 nos) accessories to be
verified as per BOQ DOC NO. P5504MEW-SWK-10-
SS-V-MTO-001.
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 7 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

7. Test Equipment

During Factory Acceptance Test, the following test equipment shall be used for testing.

Table 2 - Equipment List for FAT

Sl. Total Qty

Item Description
No. (Nos)

1. Calibration Adaptor 01

2. Gas Flow Regulator with tube 01

3. Span gas cylinders 01

UV/IR simulator for Flame

4. 01
detector

8. Factory Acceptance Test Procedure

The Factory Acceptance Test will be executed in line as described below

➢ Document Verification
➢ Material Inspection
➢ Calibration test for Gas detectors
➢ Simulation test for UV/IR detectors

8.1 Document Verification

All approved project documents and certificates shall be available with FAT Document
Stamp for the FAT inspection. The FAT document shall be checked and approval status to
be verified. The documents listed in Section 4 shall be available for F&G devices and its
items to be inspected as applicable.

8.2 Material Inspection

The material inspection ensures the manufactured detectors meets the quality
standards and meets quality acceptance satisfactorily before actual installation.

Material Inspection shall be caried out for the quantities mentioned in the table-1 at
the manufacture’s facility in Germany (Refer section 5).
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 8 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

All the observations during the inspection will be recorded in the FAT checklist (Refer
Section 9.1) and any punch point will be recorded in punch list (Appendix C).

8.3 Calibration test for Gas detector

This procedure includes both a zero calibration (fresh air calibration) and span calibration for
the gas detectors. The calibration test for the gas detectors will be carried as per the approved
ITP. Contractor/ TPI can randomly select any 2 quantities of each gas detector for the
calibration testing.

Zero calibration is performed to establish baseline readings of atmosphere that are known
to be free of toxic and flammable gases.

Span calibration is the adjustment of the gas detectors response to match that of a known
concentration of gas.

The procedure for the calibration shall be followed as per manufacturer’s standards and
recommendations (Refer the Manufacturer’s O&M manual Doc no: P5504MEW-SWK-10-SS-
V-OMM-001).

Note: Toxic gas sensors are factory calibrated & packed in a special sealed package to
prevent reaction during shipment and is recommended to open during commissioning period.
Should it be opened for inspection, it cannot be repacked in the same container for shipment,
which may affect the shelf life of the sensor.

Toxic Gas detector - Calibration Range: 0-100 ppm.

Flammable Gas Detector - Calibration Range: 0-100% LEL

8.4 Simulation test for Flame detector (UV/IR)

This procedure involves the simulation test of the flame detectors. In order to test the flame
detectors, the flame simulator can be used to simulate a fire condition which will be detected
by flame detectors and alarm symbol is generated. Contractor/ TPI can randomly select any
2 quantities of each gas detector for the Simulation testing.
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 9 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

9. FAT CHECKLIST

9.1 MATERIAL INSPECTION CHECKLIST

Equipment/ Device Name: Reference Doc:

Manufacturer: Model No:

Serial Number: Quantity:

OK NOT OK

Visual Inspection

Quantity Verification Inspection

Dimension Check

Model & Serial Number Verified

Review of factory test & conformity certificates

REMARKS

MANUFACTURER CONTRACTOR / TPI MEW/ CONSULTANT/TPI

NAME

SIGNATURE

DATE
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 10 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

9.2 CALIBRATION TEST CHECKLIST FOR GAS DETECTORS

DEVICE NAME: TAG NO:

MANUFACTURER: MODEL:
NOT
S. No Description OK Remarks
OK

1. Power ON the Gas detector with 24VDC supply.

Check the display unit of the gas detector is functioning and

2.
wait for the device initialization cycle to complete.
After the device initialization, check whether the detector
3. status is normal and a Green LED is illuminating during the
operation.

Perform zero calibration for the gas detectors and ensure the
4.
sensor is zero-point calibrated.

Perform span calibration by applying span gas and ensure

5.
the sensor is calibrated.

After completing the calibration, gas detector will return to

6.
normal operation.

REMARKS

MANUFACTURE CONTRACTOR/ TPI MEW/ CONSULTANT/TPI

NAME

SIGNATURE

DATE
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 11 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

9.3 SIMULATION TEST CHECKLIST FOR FLAME DETECTORS

DEVICE NAME: TAG NO:

MANUFACTURER: MODEL:
NOT
S. No Description OK Remarks
OK
Power ON the Flame detector with 24VDC supply and wait
1.
for the flame detector to finish the initialization.

After the device initialization, check the status of the LED

2.
flashes green at normal status.

Aim the flame simulator at the target point of the flame

3. detector. The LED in the flashes RED on pre-alarm condition
then the LED turns into steady RED in alarm condition.
REMARKS

MANUFACTURE CONTRACTOR/ TPI MEW/ CONSULTANT/TPI

NAME

SIGNATURE

DATE
 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 12 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

APPENDIX -A
Test Attendance Roster

Activity
Date
Location

Name Designation Company Signature

 FUNCTIONAL TEST PROCEDURE FOR Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FIRE AND GAS DEVICES Rev. No. : A

PROCUREMENT, CONSTRUCTION, COMMISSIONING Page 13 of 14

AND MAINTENANCE FOR UPGRADATION OF FUEL
SUPPLY SYSTEM INFRASTRUCTURE WITHIN SHUWAIKH
POWER STATION

APPENDIX -B
FACTORY ACCEPTANCE TEST (FAT) CERTIFICATE

PROCUREMENT, CONSTRUCTION, COMMISSIONING AND

PROJECT MAINTENANCE FOR UPGRADATION OF FUEL SUPPLY SYSTEM
INFRASTRUCTURE WITHIN SHUWAIKH POWER STATION
MEW CONTRACT NO: MEW/C/5504-2020/2021
PO REFERENCE PO.NO.: 000019038
CLIENT MINISTRY OF ELECTRICITY AND WATER AUTHORITY (MEW)
CONTRACTOR HOT ENGINEERING CONSTRUCTION CO.
VENDOR SPECIALISED SECURITY SYSTEMS CO
SYSTEM F&G DEVICES
FAT COMPLETION
DATE
This is to certify that the Factory Acceptance Test for the F&G devices have been
successfully conducted at the FAT location- Drager Safety, Germany according to the
factory acceptance procedure P5504MEW-SWK-10-SS-V-PPR-001.

The system was found to be in accordance with the client purchase order requirements,
Applicable specifications, procedures and per data shown in the approved drawings. The systems
are accepted and released for delivery to site.

REMARKS:

VENDOR CONTRACTOR/ TPI MEW/ CONSULTANT/TPI

NAME

DESIGNATION

SIGNATURE

DATE
 Doc No : P5504MEW-SWK-10-SS-V-PPR-001
FUNCTIONAL TEST PROCEDURE FOR FIRE AND GAS DEVICES
Rev. No. : A
PROCUREMENT, CONSTRUCTION, COMMISSIONING AND MAINTENANCE
Page 14 of 14
FOR UPGRADATION OF FUEL SUPPLY SYSTEM INFRASTRUCTURE
WITHIN SHUWAIKH POWER STATION

APPENDIX-C
PUNCH LIST
SIGNATURE
CATEG CLOSURE
S.NO. DATE PUNCHLIST ISSUED BY ACTION BY STATUS REMARKS
ORY DATE
HOTECC/
MEW/TPI
TPI