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SUB CONTRACTOR: CONTRACTOR:

CONCESSION AGREEMENT IN RESPECT OF THE OPERATION, MAINTENANCE AND

UPGRADE OF A DISTRICT COOLING CO-GENERATION PLANT (“Project”)

DESIGN, ENGINEERING, PROCUREMENT, INSTALLATION, TESTING AND

COMMISSIONING WORKS FOR AND/OR IN RELATION TO IMPROVEMENT WORKS
AND CONVERSION WORKS (“Work”)

CHILLER COMMISSIONING PROCEDURE

Document/Drawing Number: TNEC-STSB-KLIA-COM-PROC-002
Revision: A1

1 REVIEWED

2 REVIEWED WITH COMMENT

3 REJECTED

IE comments

COMMENT BY: DATE:

PREPARED BY REVIEWED BY
Revision Date Status
SEGATRANS TNEC

A 30/05/2023 Issue for review Sam Sharil

A1 26/06/2023 Issue for review Sam Sharil
 SUB CONTRACTOR: CHILLER COMMISSIONING PROCEDURE
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Table of Contents

1. PURPOSE............................................................................................................................................. 3
2. SCOPE ................................................................................................................................................. 3
3. DEFINITION .......................................................................................................................................... 3
4. chiller start up procedure ....................................................................................................................... 4
5. chiller shutdown procedure .................................................................................................................... 6
6. attachments........................................................................................................................................... 7
6.1 Attachment 1 - Location of important Valves ................................................................................ 7
6.2 Attachment 2A - How to ON XCV104X – Chilled water valve ........................................................ 7
6.3 Attachment 2B - How to OFF XCV104X – Chilled water valve....................................................... 7
6.4 Attachment 3A - How to ON FCV204X – Cooling water valve ....................................................... 7
6.5 Attachment 3B - How to OFF FCV204X – Cooling water valve...................................................... 7
6.6 Attachment 4A - How to ON EC104X – Chiller .............................................................................. 7
6.7 Attachment 4B - How to OFF EC104X – Chiller ............................................................................ 7
6.8 Attachment 5 - SENSORS CALIBRATION CERT.......................................................................... 7
6.9 Attachment 6 - RELIABILITY RUN DATA ...................................................................................... 7
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CONTRACTOR:
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1. PURPOSE
The aim of this procedure is to list out all the commissioning procedure for chiller.

2. SCOPE
This shall cover for commissioning procedure for new electrical chiller EC104 A, B, C, D, E, F in the
District Cooling Cogeneration Plant at Kuala Lumpur International Airport.

3. DEFINITION
CONTRACTOR Means TNB ENGINEERING CORORATION SDN BHD

INDEPENDENT Means person(s) appointed by CONTRACTOR to act as an independent

ENGINEER engineer for the purpose of contract

SUBCONTRACTOR Means the person(s) named as SUBCONTRACTOR in the letter of

award accepted by the SUB CONTRACTOR – SEGATRANS SDN BHD

NOMINATED Means any person or company approved by SUB CONTRACTOR to

SUBCONTRACTOR whom part of the work is subcontracted by SUB CONTRACTOR

PLANT OPERTOR Means person appointed as operator for KLIA GAS District Cooling Plant
– MAKHOSTIA SDN BHD

PROJECT Means CONCESSION AGREEMENT IN RESPECT OF THE

OPERATION, MAINTENANCE AND UPGRADE OF A DISTRICT
COOLING CO-GENERATION PLANT

WORK Means ENGINEERING, PROCUREMENT, CONSTRUCTION AND

COMMISSIOING OF IMPROVEMENT WORKS AND CONVERSION
WORKS OF THE DISTRICT COOLING COGENERATION AT KUALA
LUMPUR INTERNATIONAL AIRPORT

WORK SITE Means construction area for the project as described where the
equipment to be installed and additional areas as may be allocated or
accepted by SUB CONTRACTOR for temporary use such as
transportation, storage and offloading.

VENDOR Means supplier or manufacturer of the equipment and materials

appointed by SUB CONSTRACTOR and reviewed by CONTRACTOR
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4. CHILLER START UP PROCEDURE

This document shall be based on following specification and references:
Note:
X denotes the set number. So if the specific set of chiller is referred to, the corresponding valve /
pumps has to follow.

For example we have Chiller EC104A, EC104B, EC104C, EC104D

So generally we describe
o Chiller as EC104X
o Primary chilled water pump for each chiller as P101X
o Flow meter for chilled water across each chiller as FT104X
o On/off valve for chilled water as XCV104X
o Cooling water pump for each chiller as P201X
o Flow meter for cooling water across each chiller as FT204X
o Modulating (0 ~ 100pct adjustable) valve for cooling water as FCV204X

Before each start of chiller make sure all the existing manual valves at cooling water side and chilled
water side is opened fully. – (valve V1, V2, V3, and V4 – please refer Attachment 1)
Whereas the XCV104X and FCV104X shall be in fully closed position.

Start the chilled water flow

Turn on pump P101X, after pump turn on for 5 sec, turn ON chilled water motorized valve
XCV104X.
Note:
P101X is currently can only be controlled by the Yokogawa DCS system (under operator Mahkostia).
Whereas motorized on/off valve can be controlled by the new SCADA.

Refer Attachment 2A – how to ON the XCV104X

Check there is flow at FT104X by looking at SCADA. The rated flow shall be 840m3/hr.
Manually throttle the pump discharge isolation valve to get required flow rate from chiller
(840m3/hr). Please refer Attachment 1 for the location of the valve V5.
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Start the cooling water flow

Concurrently, turn on pump P201X, after pump turn on for 5 sec, key in the % opening of modulating
valve FCV204X (increase or decrease the % opening to achieve required flow rate 1,688m3/hr).
Note:
P201X is currently can only be controlled by the Yokogawa DCS system (under operator Mahkostia).
Whether to add in another cooling tower fan / tower will depends on the available cooling capacity of
the running towers, since all the towers are shared by a common header, and each cooling tower
could serve more than one chillers heat discharge. (under operator Mahkostia to decide).

Chiller supplier to check safety interlock and chiller ready to start up. Chiller internal controls will
check for presence of flow for chilled water and condenser water. And waiting for the SCADA to call
the chiller to ON.

From the SCADA, start the chiller by pressing the button as per instructions in Attachment 4A – how
to ON chiller

After the chiller has started, the chiller shall be monitored for the temperature and current
consumption make sure it is within acceptable level.
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5. CHILLER SHUTDOWN PROCEDURE

Note:
X denotes the set number. So if the specific set of chiller is referred to, the corresponding valve /
pumps has to follow.

For example we have Chiller EC104A, EC104B, EC104C, EC104D

So generally we describe
o Chiller as EC104X
o Primary chilled water pump for each chiller as P101X
o Flow meter for chilled water across each chiller as FT104X
o On/off valve for chilled water as XCV104X
o Cooling water pump for each chiller as P201X
o Flow meter for cooling water across each chiller as FT204X
o Modulating (0 ~ 100pct adjustable) valve for cooling water as FCV204X

The sequence to stop the chiller is always to stop the chiller first.
NEVER stop the chilled water pump or cooling water pump flow first. Doing so will damage the
chiller.

To stop the chiller, press the button on the SCADA stop chiller.
Please refer to instructions in Attachment 4B – how to OFF chiller

After the chiller has stopped, now is time to stop the pumps.
Check the XCV104X and FCV104X shall be in open/partial open position.

Stop the cooling water flow

Close the FCV204X by key in 0 pct into the pop up window.
Please refer to instructions in Attachment 3B – how to OFF FCV204X
You will see the cooling water flow slowly reduce during the closing of the valve.
Once the flow is left less than 300 m3/hr, concurrently shut off the pump P201X.
Shut off the corresponding tower fans.
Note:
P201X is currently can only be controlled by the Yokogawa DCS system (under operator Mahkostia).
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Stop the chilled water flow

Check there is flow at FT104X by looking at SCADA. The rated flow shall be around 840m3/hr.
Close the XCV104X valve (Please refer to instructions in Attachment 2B – how to OFF XCV104X)
The flow rate shall be reducing, once flow is less than 300m3/hr, immediately off the P101X.

Note:
P101X is currently can only be controlled by the Yokogawa DCS system (under operator Mahkostia).
Whereas motorized on/off valve can be controlled by the new SCADA.

Lastly, Manually close the pump discharge isolation valve at the chiller area. Please refer
Attachment 1 for the location of the valve V5.

6. ATTACHMENTS

Please read together with these:

6.1 Attachment 1 - Location of important Valves

6.2 Attachment 2A - How to ON XCV104X – Chilled water valve
6.3 Attachment 2B - How to OFF XCV104X – Chilled water valve
6.4 Attachment 3A - How to ON FCV204X – Cooling water valve
6.5 Attachment 3B - How to OFF FCV204X – Cooling water valve
6.6 Attachment 4A - How to ON EC104X – Chiller
6.7 Attachment 4B - How to OFF EC104X – Chiller
6.8 Attachment 5 - SENSORS CALIBRATION CERT
6.9 Attachment 6 - RELIABILITY RUN DATA
 CONCESSION AGREEMENT IN RESPECT OF THE OPERATION, MAINTENANCE AND UPGRADE
OF A DISTRICT COOLING CO-GENERATION PLANT (“Project”)

DESIGN, ENGINEERING, PROCUREMENT, INSTALLATION, CONSTRUCTION, TESTING AND

COMMENT RESPONSE SHEET
COMMISSIONING WORKS FOR AND/OR IN RELATION TO IMPROVEMENT WORKS AND
CONVERSION WORKS (“Works”)
Project Drawing/Document No: Drawing/Document Title: CHILLER TESTING & COMMISSIONING PROCEDURE
TNEC-STSB-KLIA-COM-PROC-002
Reference No: Abbreviation: : 1= Reviewed 2 = Reviewed with comment 3 = Reject

CRS Revision Status

Doc Review
Rev Date Doc Review Status Rev Date Doc Review Status Rev Date Doc Review Status Rev Date Status
A 08/06/23 2

Sub-Contractor Document Rev: A Date Received:

Sub-Contractor DT Number:
No Rev Contractor’s Comments Sub-Contractor's Response Status
1 A Please ensure all the instruments use in the T&C have a valid calibration Calibration certs attached
certificate.
2 A The test report shall be recorded on both condition of chilled water supply/return
temperature 4/13 deg.C and 5/13 deg.C.
3 A Please take test reading at day time where the condenser temperature close to The log reading by chiller vendor as attached
design temperature to verify chiller efficiency. We suggested take multiple reading
in 2 hours time within 10min interval.
4 A
Please attach chiller SAT compliance sheet if any.

COMMENT RESPONSE SHEET (CRS) Page 1 of 1

 Attachment 1 - Location of important valves

V3 – EXISTING MANUAL VALVE

V1 – EXISTING MANUAL VALVE

V2 – EXISTING MANUAL VAL

V4 - EXISTING MANUAL VALVE FCV204X

MOD. VALVE
XCV104X
ON/OFF VALVE

Existing CHWP

P101X

CHW out Chiller

New manual valve V5

CHW in

FT204X
FT104X Flowmeter
Flowmeter chilled cooling water
water
Attachment 2B - How to OFF XCV104X (Motorised On/Off Valve For Chilled Water)

Click on this icon XCV104C

Pop up window appear

Click on “CLOSE” button to close the valve

Then the valve icon will turn into red color. You can verify the flow by looking at the FT104C
Attachment 2A - How to on XCV104X (Motorised On/Off Valve For Chilled Water)

Click on this icon XCV104C

Pop up window appear

Click on “open” button to open the valve

Then the valve icon will turn into green color. You can verify the flow by looking at the FT104C
Attachment 3A - How to on FCV204X (Modulating Valve For Cooling Water)

Click on this icon FCV204C

Pop up window appear

Click on input area next to “Valve CV”. Key in a figure between 0% ~ 100% and press enter. Tune until
you get a flow of approx 1688 m3/hr at the FT204C.
Attachment 3B - How to OFF FCV204X (Modulating Valve For Cooling Water)

Click on this icon FCV204C

Pop up window appear

Click on input area next to “Valve CV”. Key in a figure of 0 and press enter. You will notice the flow of
approx 1688 m3/hr at the FT204C slowly reduce to 0 m3/hr once it is fully closed.
Attachment 4A - How to on Chiller remotely

Click on chiller icon EC104C

Pop up window appear, Click on”start” button

The chiller shall get the call signal, Chiller internal controls will check for presence of flow for chilled
water and condenser water. Oil pump will run for a while. Then chiller will call the Soft starter to
energise the soft starter and the chiller compresser motor will run.

The chiller icon will turn to green color, indicating the chiller compresser has started.

The chiller will ramp up and slowly the current will increase, and at the same time the chilled water
temperature out (Evap out) will drop. In any case the chiller unable to start/error/trip, it will show the
related error messages on here and the local chiller panel.
Important:

The chiller has a limit of start stop / hour of maximum 1 time only per hour and maximum 4 times per
day. And after each fail start / trip, it will have to have recycle time of 15 minutes. This is to prevent
damage to the compressor motor due to excessive restarts. Please check the root cause of the trip before
restart the chiller. Start by analysing the alarm messages displayed.
Attachment 4B - How to OFF Chiller remotely

Click on chiller icon EC104C

Pop up window appear, Click on ”STOP” button

The chiller shall get the call to stop signal, Chiller internal controls will start unloading process. Then
chiller will call the Soft starter to deenergise the soft starter and the chiller compresser motor will stop.

The chiller icon will turn to red color, indicating the chiller compresser has stopped.

Then, proceed with the shutting down of the corresponding chilled water pump and condenser water
pump and valves. Please refer to Attachment 2B and 3B for the shutting down procedure of the pumps.

Important: The chiller has a limit of start stop / hour of maximum 1 time only per hour and maximum 4
times per day. And after each fail start / trip, it will have to have recycle time of 15 minutes. This is to
prevent damage to the compressor motor due to excessive restarts. Please check the root cause of the
trip before restart the chiller. Start by analysing the alarm messages displayed.