OK N/A P/L No

1

1.01

1.02

1.03

1.04

1.05

1.06

2

2.01

2.02

2.03

2.04

2.05

2.06

2.07

2.08

2.09

3

3.01

3.02

3.03

3.04

3.05

3.06

4

4.01

Simulation Tests

(LOCAL) Heater Start via push button S2:

- Put Selector Switch S1 to LOCAL mode

-Verify Heater Bundle Element (lamp) are connected at X1 (Pt 1, 2 & 3)

-Press Heater Start pushbutton S2 to start the system. This will energize contactor relay KA1

-Verify the Potentiometer on the Control panel to manually vary the firing of the Thyristor

- Heater Bundle Element (lamp) shall be ON. Confirm voltage output at X1 (Pt 1, 2 & 3)

- Panel Fan shall be ON. Verify the panel fan is running

- Check indications Power ON (ON), Heater ON (ON), Fan ON (ON) and the rest are OFF

- Verify Heater (lamp) ON status feedback to DCS at XM1 (Pt 1&2) (XB-401)

-Verify LOCAL mode status feedback to DCS at XM1 (Pt 5&6) (ZS-401)

Measure the incoming terminals of Q1 (MCCB) to ensure that it corresponds to the supplied

incoming voltage

Switch on Q1 (MCCB) and check the outgoing voltage at the output terminals to ensure that it

corresponds to the supplied outgoing voltage

Check the rest of the circuit breakers, if any, at the incoming and outgoing terminals to ensure

that they are supplied with the correct voltage as shown in the approved drawings (Note:

Switch on each circuit breaker and check one at a time).

Lamp Test S5

- Once all circuit breakers are switched on, press Lamp Test button S5 to check for all front

panel lightings.

-Check all lamp (ON)

Fault Reset Button S4

-Press Fault Reset Button S4 to energize contact relay KA2 and KA2A. This will energize the

rest of the contact relays

-Check Power (ON), Heater OFF (ON) and the rest are OFF.

- Heater bundle space heater shall be ON. Check for voltage supply at X2 (Pt 1&2)

- The panel is now in Stand-by mode

Provide 3 incandescent light 100W connection 3-phase Delta. Signal simulation to test control

functions with visual Thyristor over the brightness of the lamp

Provide a 4-20mA connection at XM4 (Pt 5&6) and XM2 (Pt 1&2) for temperature transmitter

(TT-445) and control signal from remote set point.

Provide 24Vdc at XM3 (Pt 1&2, 3&4, 5&6 ) for Remote Start/Stop (HS-401), Remote Trip (SIS),

Remote Fault Reset (XY401)

Power Up Inspection

Ensure the incoming main circuit breaker Q1 (MCCB) is switched off. Connect incoming power

supply of 400V, 3phase 50Hz to the MCCB Terminals

TBHR- PAC11- HEATER CONTROL PANEL FOR CONDENSATE H401- INSPECTION & TEST RECORD

Ensure all electrical and mechanical connections are tightened

Check tagging of wire and terminal blocks marking

Ensure customer terminal blocks to have sufficient space for wiring

Check correct wire size and earthing terminals

Ensure finishing color is in accordance to the approved drawings

Check all installed components to be complete and mounted securely

INSPECTION/TEST

Inspect equipment for any mechanical damage

Ensure cleanliness of equipment

Visual Inspection:

Internal Circuitry Inspection

Ensure correct dimensions for the Heater Control Panel as specified in the approved drawings

Check each component ratings to be as per the BOM

Ensure all nameplates to be properly mounted as specified in the approved drawing(If

necessary)

Ensure correct mounting details as per the approved drawings.

4.02

4.03

4.04

4.05

4.06

4.07

Remote Fault Reset (XY- 402)

Simulate a Remote Stop by de-energize the 24Vdc at XM3 (Pt 5&6)

Press Fault Reset from PCS to energize contact relay KA2 and KA2A. This will energize the

rest of the contact relays

Check Power ON (ON), Heater OFF (ON) and the rest are OFF.

Heater bundle space heater shall be ON. Check for voltage supply at X2 (Pt 1&2)

The panel is now in Stand-by mode.

(LOCAL) Emergency Stop :

- Put Selector Switch S1 to LOCAL mode

- Initiate a Heater (lamp) Start as per Step 4.01

-Simulate an Emergency Stop via E-Stop S6

- Heater (lamp)System shall be tripped

- Heater Bundle(lamp) shall be OFF. Confirm no voltage output at X1 (Pt 1, 2 & 3)

- Panel Fan shall be OFF. Verify the panel fan has stopped running

- Check indications Power ON (ON), Heater OFF (ON), Emergency Shutdown (ON), System

Alarm (ON), Heater over flange temp (ON), Element over temp (ON) and the rest are OFF

-Verify Heater OFF status feedback to DCS at XM1 (Pt 1&2)

- Verify Common Fault status feedback to DCS at XM1 (Pt 3&4)

- Clear the E-stop and Fault Reset (S4) the system

(Field) Emergency Stop

- Put Selector Switch S1 to LOCAL mode

- Initiate a Heater (lamp) Start as per Step 4.01

- Simulate an Emergency Stop via E-Stop S6 (Field)

- Heater (lamp)System shall be tripped

- Heater Bundle(lamp) shall be OFF. Confirm no voltage output at X1 (Pt 1, 2 & 3)

- Panel Fan shall be OFF. Verify the panel fan has stopped running

-Check indications Power ON (ON), Heater OFF (ON), Emergency Shutdown (ON), System

Alarm (ON)Heater over flange temp (ON), Element over temp (ON) and the rest are OFF

- Verify Heater OFF status feedback to DCS at XM1 (Pt 1&2)

- Verify Common Fault status feedback to DCS at XM1 (Pt 3&4)

Clear the E-stop and Fault Reset (S4) the system

(LOCAL) Heater Stop via push button S3:

- With Step 4.01, simulate Heater (lamp) Stop by pressing the stop push button S3. This will

terminate all contact relays

- Heater Bundle (lamp) shall be OFF. Confirm no voltage output at X1 (Pt 1, 2 & 3)

- Panel Fan shall be OFF. Verify the panel fan has stopped running

- Check indications Power ON (ON), Heater OFF (ON) and the rest are OFF

- Verify Heater (lamp) OFF status feedback to DCS at XM1 (Pt 1&2) (XB-401)

- Verify LOCAL mode status feedback to DCS at XM1 (Pt 5&6) (ZS-401)

Remote Start/ Stop (HS-402)

Remote Start

-Put Selector Switch S1 to REMOTE mode

- Verify 4-20mA connection at XM4 (Pt 5&6) For TT-446

-Simulate a Remote Start by applying a 24Vdc signal to XM3 (Pt 1&2)

- Verify the Thyristor firing by varying the 4-20mA current input for TT-446 at XM1 (Pt 1&2)

- Heater Bundle (lamp) shall be ON. Confirm voltage output at X1 (Pt 1, 2 & 3)

- Panel Fan shall be ON. Verify the panel fan is running

- Check indications Power ON (ON), Heater ON (ON), Fan ON (ON) and the rest are OFF

- Verify Heater (lamp) ON status feedback to DCS at XM1 (Pt 1&2) (XB-401)

- Verify REMOTE mode status feedback to DCS at XM1 (Pt 5&6) (ZS-401)

Remote Stop

-Simulate a Remote Stop by de-energize the 24Vdc at XM3 (Pt 1&2)

- Heater Bundle (lamp) shall be OFF. Confirm no voltage output at X1 (Pt 1, 2 & 3)

- Panel Fan shall be OFF. Verify the panel fan has stopped running

- Check indications Power ON (ON), Heater OFF (ON) and the rest are OFF

-Verify Heater (lamp)OFF status feedback to DCS at XM1 (Pt 1&2) (XB-401)

- Verify REMOTE mode status feedback to DCS at XM1 (Pt 5&6) (ZS-401)

Remote Trip (SIS)

- Simulate a Remote Stop by de-energize the 24Vdc at XM3 (Pt 3&4) (SIS)

-Heater Bundle (lamp) shall be OFF. Confirm no voltage output at X1 (Pt 1, 2 & 3)

- Check indications Power ON (ON), Heater OFF (ON), System Alarm ON (ON), Heater Flange

Overtemp (ON), Element Overtemp (ON) and the rest are OFF

- Verify Heater (lamp)OFF status feedback to DCS at XM1 (Pt 1&2)

- Verify REMOTE mode status feedback to DCS at XM1 (Pt 5&6)

4.08

4.09

4.10

4.11

Simulation for THC1 (Heater Flange Over-Temperature Trip)

- Connect a process meter with 4-20mA current input at XM4 (Pt 1&2)

- Press Fault Reset button S4 and Heater Start button S2

- Vary the process meter with current injection from 4mA to 20mA at XM4 (Pt 1&2). As the

current injection increases, it simulates an increase in the heater flange temperature as shown

on the THC1 display

- When the temperature rises above the THC1 set point, THC1 controller will send out a signal

and opens the relay, KA4. The system will be tripped as it has detected a Heater Flange Over

Temperature in the heater system

- Check indications Power ON (ON), Heater OFF (ON), Heater Flange overtemp (ON), System

Alarm (ON) and the rest are OFF

- Heater Bundle (lamp) shall be OFF. Confirm no outgoing voltage to heater bundle (lamp) at

X1 (Pt 1,2&3)

- Verify Heater (lamp) OFF signal feedback to DCS at XM1 (Pt 1&2)

- Verify Common Fault signal feedback to DCS at XM1 (Pt 3&4)

- Verify Heater Flange Over-Temperature trip signal feedback to DCS at XM1 (Pt 7&8) (XZA-

401A)

- Heater system is tripped and cannot restart. System can only be reset when the heater flange

temperature has dropped below the THC1 set point temperature

Simulation for THC2 (Heater Element Over-Temperature Trip)

-Connect a process meter with 4-20mA current input at XM4 (Pt 3&4)

- Press Fault Reset button S4 and Heater Start button S2

- Vary the process meter with current injection from 4mA to 20mA at XM4 (Pt 3&4). As the

current injection increases, it simulates an increase in the heater element temperature as

shown on the THC2 display

- When the temperature rises above the THC2 set point, THC2 controller will send out a signal

and opens the relay, KA5. The system will be tripped as it has detected a Heater Element Over

Temperature in the heater system

-Check indications Power ON (ON), Heater OFF (ON), Element Overtemp (ON), System Alarm

(ON) and the rest are OFF

- Heater Bundle (lamp) shall be OFF. Confirm no outgoing voltage to heater bundle (lamp) at

X1 (Pt 1,2&3)

- Verify Heater OFF signal feedback to DCS at XM1 (Pt 1&2)

-Verify Common Fault signal feedback to DCS at XM1 (Pt 3&4)

-Verify Heater Element Over-Temperature trip signal feedback to DCS at XM1 (Pt 9&10)

-Heater system is tripped and cannot restart. System can only be reset when the heater

element temperature has dropped below the THC2 set point temperature

Earth Leakage Trip

-Repeat Step 4.01

- Simulate an Earth Leakage Fault via the Test function on the Earth Leakage Relay Unit,

ELR

- Verify indications Power ON (ON), Heater OFF (ON), Earth leakage trip (ON), System Alarm

(ON), Heater over flange temp (ON), Element over temp (ON) and the rest are OFF

- Heater Bundle (lamp) shall be OFF. Confirm no outgoing voltage to heater bundle (lamp) at

X1 (Pt 1,2&3)

- Verify Heater (lamp) OFF signal feedback to DCS at XM1 (Pt 1&2)

- Verify Common Fault signal feedback to DCS at XM1 (Pt 3&4)

Thyristor Trip

-Repeat Step 4.01

- Simulate an Thyristor trip via the shorted SCR

- Verify indications Power ON (ON), Heater OFF (ON), System Alarm (ON), Thyristor Trip (ON)

and the rest are OFF

- Heater Bundle (lamp) shall be OFF. Confirm no outgoing voltage to heater bundle (lamp) at

X1 (Pt 1,2&3)

- Verify Heater (lamp) OFF signal feedback to DCS at XM1 (Pt 1&2)

- Verify Common Fault signal feedback to DCS at XM1 (Pt 3&4)