MANUFACTURE QUALITY PLAN

Production Flow Diagram

DRAWING &
DESIGN APPROVAL
BY CLIENT

MATERIAL PURCHASE

MATERIAL RECEIVING &

DOCUMENTED

PRODUCTION & ASSEMBLY

QUALITY CONTROL

FACTORY INTERNAL TEST

RUN
& AS BUILT
DOCUMENT PREPARATION
FOR
FAT & DELIVERY
FACTORY ACCEPTANCE TEST
& CERTIFICATION

PACKING & DELIVERY

SITE INSTALLATION
ASSISTANCE

DRAWING &
DESIGN APPROVAL
BY CLIENT

MANUFACTURE QUALITY PLAN

Rev 1.2013

With referenced to Clients project specific requirement and related Standard applied . All
design & drawing & material submitted to client for review & approval , Any correction made
re-submit for approval by client.
Production , FAT & SAT will all be based on this approval.
Hvac production calculation base on ARI , ASHRAE , SMACNA and NEC standard.
Design & drawing included but not limited to :
1. General layout
2. Data sheet
3. Specification
4. Block diagram
5. P&ID diagram
6. Hvac Design calculation
7. Fresh air transit Vs Gas damper closing calculation
8. Load calculation
9. Cable schedule
10. Hvac design drawing
11. Electrical diagram
12. Control Panel drawing
13. PLC Ladder logic development & Listing
14. Utility consumption / Load list
15. Grounding system planning
16. Material take off
17. Inspection Test Plan
18. Factory acceptance procedure
19. Operation manual book

MATERIAL PURCHASE

Material involved in the project purchaced through local authorized agent if any , or direct
imported from manufacturer.
All material strictly comply to type number / catalog number / specification as said in the
approval document, and brand new.
A copy of un-priced order may be available for client reference only.
Depend , some material duty may be payed by Client or included in the contract.
MATERIAL RECEIVING &
DOCUMENTED

All material and/or component received accompany with a Certificate ( COO

/Conformance/Manufacture certificate/ third party certification such FM / UL / Marine etc ).
Material include :
- Fins ( aluminium / copper / stainless steel & Tube )
- Metal sheet ( SS316L , Mild sheet steel / others )
- Compressor , Motor , Blower , Fan , Gas damper , Dampers etc
MANUFACTURE QUALITY PLAN

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Cables , Lug
Electrical components ( breaker , magnetic contactor , relay etc )
Insulation material
Coating material
Box
ETC

Quality check apply for packaging condition , appearance. Although rare , Cracks /
moisture / dirt found may be subjected to rejection for particular material , and report is
made and documented.
Material received checked for Type no / Part no / Specs , of which must be exactly the same
as stated in Purchase Order. Any deviation will be rejected. We apply zero tolerance for
material quality impair.
Substitue is not allowed.
Certificate & manual are documented.

PRODUCTION & ASSEMBLY

Once the material is received , production may be started.

Production :
1. Sheet metal ( cutting , forming , CNC punching ) for housing of AHU , Condensing
and Pressurizing unit and Ducting.
2. Metal sheet welding for structure & ducting.
3. Coils fabrication
QC :
1. Leak Test for Coils produced. ( 400 Psig for 60 minutes & water tank submerged ).
2. Metal sheet surface finishing after welding.
Assembly guideline :
1. Follow color codes.
2. Follow cable ampacity rating.
3. Follow cable lug sizing code.
4. Follow hazardous classification requirements and material.
5. Maximum 2 cable lug in one terminal block.
6. Every equipment must be hard grounded.
Assembly :
1. Assembly of all component ( compressor , Fan , blower , motor etc ) to form a
complete Hvac unit.
2. Refrigerant pipe welding work.
3. Electrical wiring & laying.
QC :
1. Leak test for refrigerant piping after spool forming/welding.
MANUFACTURE QUALITY PLAN

Rev 1.2013

2. Continuity & Insulation test with 500V tester.

FACTORY INTERNAL TEST
RUN
& AS BUILT
Electronic measuring instrument used :
- Clamp ampere meter ( RMS )
- AVO meter ( RMS )
- Insulation tester 500/1000 V
- Air flow meter
- Thermometer ( dry & wet bulb )
- Digital thermometer
- Non contact infra red thermometer
- Noise meter
- RH humidity meter
- Computerized temperature data logger ( Cooling capacity measurement )
- Vibration meter
After assembly , internal test run for individual component and Hvac system check.
Test data is recorded in the following form.

HVAC TEST RECORD

NO

DESCRIPTION

Test Start time:

- Date
- Run Time ( Minute )

Record Time :
- Start record
- Stop record
Electrical consumption ( Ampere )

AHU A
TAG NO.FP-HVAC000A

AHU B
TAG NO. FP-HVAC000B

- Compressor ( A )
- Motor Fan #1 ( A )
- Motor Blower ( A )
- Press Fan motor ( A )
Refrigerant side
- Suction Pressure (Psig)
- Discharge Pressure (Psig)
Air Side Condenser
- Face Area Fan ( m2 )
- Velocity ( m/s )
- Ambient Temp ( o CDB )
- Output Air Temp ( o CDB )
- T Condenser ( o C )
Noise level ( dB ) 3 m from unit

MANUFACTURE QUALITY PLAN

Rev 1.2013

Air side Evaporator

- Face area blower (m2 )
- Velocity blower ( m/s )
- Fresh air intake
- Output Air

A = Ampere / Phase at 460Vac 60 Hz

Psig = Pressure per Square Inch gage
M2 = Square meter
m/s = Meter per second
o
C = Centigrade Celcius
o
CDB = Celcius dry bulb
o
CWB = Celcius wet bulb
T Condenser ( o C ) = Output Ait Temp ( o CDB ) Ambient Air Temp ( o CDB )

Record is compare to equipment data sheet. Normally capacity used maximum not
exceeding 80% of maximum equipment rated load.
Output data / air flow / temp / pressure must meet design parameter criteria. Any anomalies
is corrected / adjusted.
Hvac capacity recorded with the following ASHRAE Chart as :

MANUFACTURE QUALITY PLAN

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PH Enthalpy diagram
MANUFACTURE QUALITY PLAN

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COP
MANUFACTURE QUALITY PLAN

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Insulation test Records

MANUFACTURE QUALITY PLAN

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HVAC COIL RESISTANCE & INSULATION TEST RECORD

NO

DESCRIPTION

Winding resistance test

AVO Meter

COMPRESSOR

MOTOR
BLOWER

MOTOR
FAN

MOTOR
PRESS FAN

T1-T2 ( ohm )
T1-T3 ( ohm )
T2-T3 ( ohm )
2

Insulation test
MEGGER 500 Volt
T1 GND ( M Ohm )
T2 GND ( M Ohm )
T3 GND ( M Ohm )

Note:

DOCUMENT PREPARATION
FOR
FAT & DELIVERY

Preparation for Factory Acceptance Test or FAT based on the project document above.
Records and Measurement are prepared for FAT.
MANUFACTURE QUALITY PLAN

Rev 1.2013

High visible tapes is mounted to mark the FAT boundary area.

FACTORY ACCEPTANCE TEST

& CERTIFICATION

FAT test is intended to proof that the finish factory product has meet or exceed the design
requirement.
Test may be include :
- Dimensional check
- Functional check
- Air flow
- Temperature ouput
- Humidity
- Pressure
- Cooling capacity & COP
- Response of gas damper
- Backup scheme
- Alarm handling
- Alarm logging & print out
- Interface operability with other system
- Leak test
Certification by third party certification institution available upon request by contract.
Such as:
- Sucofindo
- BKI ( Biro Klasifikasi Indonesia )
- Surveyor Indonesia

PACKING & DELIVERY

A packing list contain information on :

- Client name
- Project no
- Content
- Name of equipment
- Bill of material
- Certificate of lifting & NDT report on welded steel ( if any )
- Weight
- MSDS ( Material safety data sheet ) if contain liquid or gas substance
All pipes and cables must be end-cap for water proofing.
Equipment must be whole plastic wrapping.
All openings / flanges / joints must be secured for water proofing.
All Ducting must be plastic wrapping for water proofing.
Ensure all equipment contain is secured and bolted to packing bottom and not moving
during transportation , lifting.
MANUFACTURE QUALITY PLAN
Rev 1.2013

SITE INSTALLATION
ASSISTANCE
& TRAINING and
DOCUMENTATION
Our site engineer is available for installation or supervision , to ensure that all engineering
aspect is meet. This include mobilisation on-site , un-packing , installation , testing and
commissioning.
Training for operation & maintenance staff for Client to ensure the System is understood and
easyly and safely operated and maintained beyond installation.
Whether it is electro-mechanical or PLC based system , instruction is clearly written and
explain to operation staff.
A operation manual of the system is provided.
All documents included technical manual ( softcopy and print out ) is provided.

Notes :

MANUFACTURE QUALITY PLAN

Rev 1.2013