PROJECT SUB ITEM OWNER MAIN CONTRACTOR MANUFACTURER

PACKAGE 2 : SEMARANG PUMPING STATION SCREEN FACILITIES & ROLLER GATES SATKER PENGEMBANGAN PENYEHATAN LINGKUNGAN PERMUKIMAN JAWA TENGAH PT. GRUNDFOSS POMPA - PT. BRANTAS ABIPRAYA P.T. AZYMUTH CITRA PERKASA

PERFORMANCETEST PROCEDURE
NO.:J001/PR001 ROLLERGATE

PreparedBy Prepared Knowledge Approved

Company PT.AzymuthCitraP GrundfosBrantasJV OrientalConsultant SatkerPPLP

Representative TjahjotoAriW DidietARaharjo MitsuoMiura SuharsonoA.B.

Signature

Date

PERFORMANCE TEST PROCEDURE

FOR ROLLER GATE AT WORKSHOP
J-001-ACP-12 J-001-PR-001
Revision 0 Page 1 of 4

TABLE OF CONTENT
1 2 3 4 5 6 PURPOSE APPLICATION REFERENCES DEFINITION RESPONSIBILITIES PROCEDURE

PERFORMANCE TEST PROCEDURE

FOR ROLLER GATE AT WORKSHOP
Q-019-ACP-11 J-001-PR-001
Revision 0 Page 2 of 4

1. PURPOSE This procedure covers the test for Roller Gates at PT Azymuth workshop before installing on site Package C2 Semarang Pumping Station and Retarding Pond. 2. APPLICATION

Applies to the all 5 units Roller Gate including motor actuator exclude rubber seal and

3. DEFINITIONS

PPLP OC GBJV ACP

: (Satker PPLP) Satker Pengembangan Penyehatan Lingkungan Pemukiman shall mean the owner of this Project : (Oriental Consultant) shall mean Consultant for this project, and on behalf Satker PPLP : (Grundfos Brantas Joint Venture) shall mean Main Contractor : (PT. Azymuth Citra Perkasa) shall mean Manufacturer

4. RESPONSIBILITIES

PPLP OC GBJV ACP

: Review of report : Check, review and Approved report of inspection test : Witness, review and approval inspection test report : - Perform fabrication and test as per scope of work - Prepare report of fabrication and test and submit to GBJV for approval

5. PROCEDURE

5.1. Preparation for test Prepare the equipment and tools to be completed and ready for use Roller gate shall be marked RG A or RG B until RG E on the skin plate prior test. Review report test inspection 5.2. Support frame Support frame are the finished fabricate material item RG-04 Support frame will be used for hanging the actuator and roller gate with additional stiffener for supported frame.

PERFORMANCE TEST PROCEDURE

FOR ROLLER GATE AT WORKSHOP
Q-019-ACP-11 J-001-PR-001
Revision 0 Page 3 of 4

5.3. Motor Actuator The approved specification of motor actuator : Brand : AUMA Type : SA 14.6 Power : 3ph / 380 VAC / 50 Hz / 1,6 kw Gear Box : GK 16.2 Ratio 4 : 1 specification of test motor actuator shall be same with approved specification, and its will be used for performance testing for all five Roller Gate in workshop before shipment. If the test motor specification different with approved specification, the test motor will be used for performance testing for only 2 roller gate at first shipment, the remaining 3 roller gates shall use the test motor with specification as approved by OC.

5.4. Overhead crane condition at workhop Height span : 4.5 meters Overhead Crane max load : 14 tons Open closed for test will be : 1.5 meters 5.5. Performance Test. Performance Test for gate will shop operated from fully closed to the opened position under a no-flow condition, to demonstate that the gate leaf is workable. The test shall cover followings : 5.4.1. Document Inspection - ML (Material List) - Installation Plan - Performance Test Procedure 5.4.2. Visual Inspection - All gates are to be visually inspected - Painting Judgment for actuator and base frame - Evaluation of visual inspection result 5.4.3. Measurement Inspection - Major dimension to be measurement and compared to drawing - Evaluation 5.4.4. Actuation Inspection

ATTACHMENT
Page 4 of 4

1. Material List (ML) 2. Installation Plan 3. Performance Test Data Report

PT AZYMUTH CITRA PERKASA

MATERIAL LIST DETAIL Doc. No. Title Qty Job No. Project No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Round bar Pipe Cap Round bar Oiless bush Round bar Plate Plate Plate Plate Plate Plate Plate Bolt Plate Plate Anchor bar Plate Plate Plate Plate Plate Plate Plate Plate Anchor bar Anchor bar Plate Plate Bolt Plate Channel UNP Channel Plate

: 001/PLD/RG/J-001-ACP-12 : ROLLER GATE "A" : 1 UNITS : J-001/ACP/12 : Package C2 Semarang Pumping Station Name of Good Part No. Dwg No. PN
Gate Spindel Spindle Cover Spindle Cover Side Roller Oiless Bush Shaft Side Roller Rib side roller Support side roller Base side roller Frame Frame Frame Rib Frame Bolt Frame Rib Frame Rib Tapper block Tapper block Frame Rib Base Frame Base Frame Base Frame Base Frame Base Frame Base Frame Lintel Lintel Lintel Lintel Frame Actuator Frame Actuator Frame Actuator Frame Actuator RG-02 RG-02 RG-02 RG-04 RG-04 RG-04 RG-04 RG-04 RG-04 RG-05 RG-05 RG-05 RG-05 RG-05 RG-05 RG-05 RG-05 RG-05 RG-05 RG-05 RG-06 RG-06 RG-06 RG-06 RG-06 RG-06 RG-06 RG-06 RG-06 RG-06 RG-07 RG-07 RG-07 RG-07 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 8A 1 2 3 4 5 6 6 7 8 9 1 1 1 2 4

Date Revision Prepared by

: 3 Oct 2012 :2 : Eko

Size (1)
10.00 10.00 10.00 10.00 10.00 10.00 10.00 M 10.00 10.00 30.00 16.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 M 10.00 200.00 200.00 10.00

(2)
80 SCH 100 80 50 30 60 150 150 310 65 65 450 12 100 100 12 60 60 65 232 310 200 200 200 12 12 397 65 12 400 75 75 150

(3)
6000 40 0 30 44 75 100 150 150 5700 5700 300 5700 45 450 300 200 100 100 300 4000 600 4620 110 484 200 200 4000 352 45 600 7 7 600

(4)
L 3000 L L L L

(5)

(6)

Qty 2 unit
2 2 2 4 4 4 16 16 4 4 4 8 2 8 4 14 56 2 2 8 1 2 1 16 2 14 2 1 2 4 2 2 2 3

Weight (kg)
482 96 5 3 2 8 29 7 565 119 12 410 0 14 34 10 3 2 12 74 30 74 28 15 3 0 127 4 0 38 299 299 21

Material Spec.
SS 304 STPG sch 40 STPG sch 40 SS 304 Bronze SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 400 SS 400 SS 400 SS 400

Remark

L L

L 9 9 4,620 4,620

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PT AZYMUTH CITRA PERKASA

MATERIAL LIST DETAIL Doc. No. Title Qty Job No. Project No.
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Plate Bolt Checkered Plate Plate Plate Rubber long Rubber long Rubber corner Rubber corner Rubber corner Rubber long Rubber long Plate Plate Plate Plate Plate Plate Bolt Nut & Ring Channel UNP Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Main Roller

: 001/PLD/RG/J-001-ACP-12 : ROLLER GATE "A" : 1 UNITS : J-001/ACP/12 : Package C2 Semarang Pumping Station Name of Good Part No. Dwg No. PN
Frame Actuator Base Frame Actuator Frame Actuator Skin Plate Skin Plate Rubber Seal Rubber for spare part Rubber Seal Corner Rubber for spare part Rubber for spare part Rubber Seal Rubber for spare part Clamp Seal Base seal Clamp Seal Base seal Clamp Seal Base seal Bolt Seal Top Channel Horisontal Beam Horisontal Beam Horisontal Beam pad roller Side Plate vertical plate vertical plate vertical plate vertical plate vertical plate vertical plate vertical plate vertical plate stifener Roller RG-07 RG-07 RG-07 RG-08 RG-08 RG-09 RG-09 RG-09 RG-09 RG-09 RG-09 RG-09 RG-10 RG-10 RG-10 RG-10 RG-10 RG-10 RG-10 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-11 RG-12 3 4 5 1 2 1 1 2 2 2 3 3 1 1 2 2 3 3 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1

Date Revision Prepared by

: 3 Oct 2012 :2 : Eko

Size (1)
10.00 M 10.00 10.00 10.00 10.00 10.00 10.00 10.00 10.00 350.00 10.00 10.00 10.00 10.00 12.00 12.00 12.00 12.00 12.00 10.00 10.00 10.00 10.00 10.00 12 1220 505 50 50 50 50 50 50 50 60 60 60 60 60 60 M10 100 330 150 120 130 360 350 350 350 80 350 350 350 80 238 430

(2)
68 45

(3)
186 L

(4)

(5)

(6)

Qty 2 unit
16 12 0 3 1 2 0.4 2 0.4 2 1 0.2 2 2 1 1 1 2 98 1 3 4 2 4 2 2 2 2 2 2 2 2 2 2 4

Weight (kg)

Material Spec.
16 SS 400 0 SS 304 SS 400 697 SS 304 96 SS 304 Neoprene Neoprene Neoprene Neoprene Neoprene Neoprene Neoprene 22 SS 304 22 SS 304 19 SS 304 19 SS 304 19 SS 304 22 SS 304 SS 304 265 SS 304 328 SS 304 199 SS 304 80 SS 304 6 SS 304 165 SS 304 66 SS 304 46 SS 304 40 SS 304 5 SS 304 55 SS 304 39 SS 304 33 SS 304 4 SS 304 13 SS 304 279 SS 304

Remark

2380 2380 125 125 275 275 275 125 125 2280 2280 4026 4026 3906 2280 x 10 4142 4142 4142 150 2380 985 690 590 330 985 690 590 330 330 60

2152 2152 275 275 275 3610 3610

55 10

L 4,142 L

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PT AZYMUTH CITRA PERKASA

MATERIAL LIST DETAIL Doc. No. Title Qty Job No. Project No.
70 71 72 73 74 75 76 77 78 79 Bush Oilles Round bar Plate Plate Plate Plate Pipe Plate Plate Plate Empty

: 001/PLD/RG/J-001-ACP-12 : ROLLER GATE "A" : 1 UNITS : J-001/ACP/12 : Package C2 Semarang Pumping Station Name of Good Part No. Dwg No. PN
bush roller Shaft Roller Key Plate Hanger Rib Hanger Plate Base Plate Pedestal Pipe Pedestal Stiffener Plate Pedestal Stiffener Plate Pedestal Flange RG-12 RG-12 RG-12 RG-13 RG-13 RG-14 RG-14 RG-14 RG-14 RG-14 2 4 5 1 2 1 2 3 4 5

Date Revision Prepared by

: 3 Oct 2012 :2 : Eko

Size (1)
5.00 10.00 12.00 12.00 80 75 30 40 150 300 SCH 143 93 210

(2)

(3)
50 364 100 130 160 400 40 860 860 210 L

(4)

(5)

(6)

Qty 2 unit
4 4 4 8 2 2 2 2 2 2

Weight (kg)
8 51 0 3 5 23 28 19 13 7 5,538

Material Spec.
SS 304 SS 304 SS 304 SS 304 SS 304 SS 400 SS 400 SS 400 SS 400 SS 400

Remark

4 10.00 10.00 10.00

860

Pedestal Pedestal Pedestal Pedestal Pedestal

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PERFORMANCE TEST
INSTALLATION PLAN

Item Ref drawing Date Owner Consultant Main Contractor Manufacturer Project

: : : : : : : :

DESCRIPTION Roller Gate "A" RG - 01 To RG - 12 8 Oktober 2012 Satker PPLP Oriental Consultant Grundfos - Brantas JV PT. Azymuth Citra Perkasa Package C2 Semarang Pumping Station

Gate Leaf Actuator Stem Connection Shaft Main Wheel

: : : : : : :

DIMENSION & DATA 2400 x 4200 SA. 14.6 dia 63 x 4330 dia 50mm dia 430 mm (No assembly for the test)

RG"A"
2400 OPENPOSITION

MaxCranespan:4500

420 0

EL+1.9 Openposition

2400

RG"A"
CLOSEDPOSITION 1500

travelling distance fortestonly,due tocranespan

EL+0.7 Closedposition

PERFORMANCE TEST
DATA REPORT

Item Ref drawing Date Owner Consultant Main Contractor Manufacturer Project

: : : : : : : :

DESCRIPTION Roller Gate "A" RG - 01 To RG - 12 8 Oktober 2012 Satker PPLP Oriental Consultant Grundfos - Brantas JV PT. Azymuth Citra Perkasa Package C2 Semarang Pumping Station

Gate Leaf Actuator Stem Connection Shaft Main Wheel

: : : : : : :

DIMENSION & DATA 2400 x 4200 SA. 14.6 dia 63 x 4330 dia 50mm dia 430 mm

Visual Check :

Main Dimension Check 1- Gate Leaf - Width - Height - Thickness 2- Frame

- Frame spacing on Left - Frame spacing on Right - Base frame width (detail II) - Base frame lengthh (detail II)

Reference Drawing ( mm ) 4200 2400 350 450 450 232 4000 430 65

Actual Measurement 1 2 3 4

Result

3- Main Wheel (diameter) 4- Shaft of Main Wheel

Actution Inspection 1- Closed Position 2- Open Position

Hoisting speed 190.46 mm/min 190.46 mm/min

Actual Measurement

Result

Approved by, Oriental Consultant on behalf of Satker PPLP

Witness by, Grundfos - Brantas JV

Prepared by, PT. Azymuth Citra Perkasa