Project Test Plans Preparation Guide. Advanced Wastewater Treatment Plant. Version 1.0

Transcription

1 Project Test Plans Preparation Guide Advanced Wastewater Treatment Plant Sacramento Regional County Sanitation District Version 1.0 September 2012

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3 Project Test Plans Preparation Guide Contents 1.0 Introduction Relationship with Other District Design Standards General Project Test Plans Preparation Description Test Plan Identification Pre-Operational Testing Functional Checkout Performance Test Operational Test Plan Preparation hour Test day Operational Test day Reliability Test Plan Test Plan Examples Schedule Appendices Appendix A. Functional Checkout Form Example Appendix B. Performance Test Form Example Appendix C. 48-Hour Pre-Operational Test Plan Example Appendix D. 10-Day Operational Test Plan Example Appendix E. 30-Day Reliability Test Plan Example Sacramento Regional County Sanitation District Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012 i

4 Project Test Plans Preparation Guide This page intentionally left blank Sacramento Regional County Sanitation District Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012 ii

5 Project Test Plans Preparation Guide 1.0 Introduction The purpose of this Project Test Plans Preparation Guide is to establish an understanding of content requirements for Designer-produced Test Plans for Sacramento Regional County Sanitation District (District) projects under the Advanced Wastewater Treatment Plant (AWTP) Program. 1.1 Relationship with Other District Design Standards This document is one component in a suite of District Design Standards. The standards are created and maintained in order to provide consistency and efficiency among design projects within the District. The standards clearly document requirements, issues, decisions, products, procedures, etc. that have reached general consensus of District staff. Each component of the standards is targeted for a specific purpose. The purpose of this document is as stated above. The components of the District Design Standards include: Design Contract Requirements Presents the content requirements for contract documents prepared for design projects. Design Guidelines Describes discipline-specific District design preferences above and beyond applicable codes and standards. Guide Specifications A library of technical specifications available for project use. CAD/BIM Standards Standards to be used on computer aided drafting (CAD) drawings and Building Information Model (BIM) requirements for data and file management. Standard Drawings and Typical Details A library of CAD drawings common across all projects and typically used details available for use by the Designer. Project Test Plans Preparation Guide Describes the level of effort the District requires of the Design Engineer to develop plans for subsequent use and implementation by the Contractor during facility commissioning and startup. Operations Manual and Training Development Guide Standards to follow in the preparation of operations manuals and O&M training programs for the District. Additional requirements related to design execution, deliverables, and designer coordination with the AWTP Program Management Office (PMO) and District staff will be contained in the Request for Proposal (RFP) for the specific design project. Particular reference is made to the Reliability-Centered Design (RCD) process to be implemented on projects involving treatment facilities and related equipment. Performance characteristics for testing and measurement will largely be identified during the RCD workshops outlined in each project-specific RFP. Sacramento Regional County Sanitation District 1-1 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

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7 Project Test Plans Preparation Guide 2.0 General This document provides the Design Engineer with guidelines for preparing the Project Test Plans to be used during the Commissioning Phase of the project (i.e., commissioning and startup). The Project Test Plans will include Pre-operational (PREOP) testing and Operational Testing (OP TEST). The completed Project Test Plans will be provided as part of the Contract Documents and must conform to District standards. PREOP testing includes all testing conducted during construction and is located in the technical specifications. PREOP testing must be strictly documented to ensure all tests were performed, witnessed, and resulted in the desired outcome. All PREOP testing must be completed and documented to the satisfaction of the District prior to starting the OP TEST. OP TEST requirements are located in District Guide Specification Section Commissioning and lists all the PREOP tests, including any special sub-system tests, and describe the exact requirements of the OP TEST, including the OP TEST schedule of activities. The Design Engineer shall prepare for inclusion into the Contract Documents the Project Test Plans for subsequent use and implementation by the Contractor during facility pre-operational testing, commissioning, and startup. Test plans will be as detailed as possible without knowledge of the specific equipment that will be installed. The Design Engineer also shall prepare a schedule of all activities identified in the OP TEST for inclusion in the Appendix in the contract documents -Test Plan. This schedule will be prepared with the knowledge that specific dates will change as construction progresses. It will be the responsibility of the Contractor to ensure this schedule is kept updated and to provide the District daily and threeweek look-ahead schedules. The Contractor also will follow the required protocol in notifying the District of all test activities. The Design Engineer is responsible for preparing an initial schedule and for detailing notification protocols in the Project Test Plans. The purpose of including the Project Test Plans in the Construction Documents is to make the Contractor aware of the specific level of effort the District requires to document equipment and system preparedness after construction and to ensure the Contractor s bid price includes provisions for carrying out the detailed test procedures that must be followed prior to commissioning and startup of all or part of the facility. The Project Test Plans prepared by the Design Engineer will be included in the Contract Documents as an appendix to the Technical Specifications, Section Commissioning. In addition, the Design Engineer must recognize the level of effort needed to prepare the Project Test Plans. The Design Engineer must submit an outline of the Project Test Plans as part of Design Submittal No. 1 (DS-1), a draft must be included as part of DS-2, and the draft final must be included as part of DS-3. The final Project Test Plans will be submitted by the Design Engineer for approval after all mechanical, electrical, and instrumentation equipment submittals have been approved. The Project Test Plans will include a section detailing the requirements that all commissioning and startup personnel will follow coordinating necessary activities with the District through the District s Commissioning Coordinator. These activities include, but are not limited to, proper Sacramento Regional County Sanitation District 2-1 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

8 Project Test Plans Preparation Guide planning, scheduling, and notification procedures, access requests, and shutdown/tie-in procedures. The Project Test Plans will include a section detailing all safety procedures that must be complied with during commissioning and startup activities. This will include, but not be limited to, discussion on proper personal protective equipment, lockout/tag-out procedures, and other District-required safety programs. Sacramento Regional County Sanitation District 2-2 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

9 Project Test Plans Preparation Guide 3.0 Project Test Plans Preparation The Design Engineer shall prepare the Project Test Plans for subsequent use and implementation by the Contractor as part of commissioning and startup. Project testing is required to ensure all mechanical, electrical, and instrumentation equipment provided or installed in association with the various stages of Work comprising the Project have been stored, maintained, assembled, serviced, aligned, connected, calibrated, and adjusted in accordance with the Construction Documents and the manufacturers recommendations prior to being placed into service. Project testing shall be divided into two distinct stages: PREOP testing and the OP TEST. The OP TEST cannot begin until the PREOP testing is completed and documented to the satisfaction of the District. 3.1 Description The District s PMO will be responsible for maintaining the Master Test Log of all forms required to document all Project testing. Requirements of the Design Engineer to record the mechanical, electrical, or instrument unit description and equipment numbering are described in the District s Design Contract Requirements. The completed forms required for all tests will include item description and equipment numbers, test description, date, data collected, observations, and the legible full name and initials of representatives of the manufacturer, Contractor, and District witnessing the testing. In addition, each test report form will include records of the manufacturer, common functional description, model number, and serial number of equipment used during the test for any purpose including, but not limited to, measurement, monitoring, analytical analysis, etc. Example report forms are provided in the attached appendices. Data entry fields in the electronic test forms will be linked to the process and instrumentation diagram (P&ID) drawings via a structured query language (SQL) server database so there is only one location to add, delete, or modify testing data and equipment information. Refer to the District s CAD/BIM Standards for additional information. Each installation test procedure and associated report form will be assigned a procedure number with a prefix consisting of the governing specification section and a unique alpha or numeric suffix. Installed piping test procedures are assigned numbers with a prefix consisting of the governing specification section and piping system number with a unique alpha or numeric suffix. For multiple equipment items, a numeric suffix is added following the alphabetic suffix (e.g., C1, C2, etc.). 3.2 Test Plan Identification Identify each test plan by using the associated equipment specification number plus an alphabetic suffix as follows: Factory Tests Delivery Acceptance Tests A B Sacramento Regional County Sanitation District 1 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

10 Project Test Plans Preparation Guide Pre-operational and Start-up Checkout Performance Test 48-hour pre-operational test plan 10-day operational test plan 30-day reliability test plan C D E F G Sacramento Regional County Sanitation District 2 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

11 Project Test Plans Preparation Guide 4.0 Pre-Operational Testing All PREOP testing requirements will be detailed in the Project Test Plans prepared by the Design Engineer and shall be included in the Contract Documents. All PREOP test forms shall be located and numbered sequentially with the technical specification sections or included per discipline as an appendix to the Project Technical Specifications, Section Commissioning. District Guide Specifications include the standard PREOP test forms, but these shall be supplemented by the Design Engineer as necessary to accommodate any specific requirements in the Project. Factory testing, performance testing, functional checkouts, vendor system startup, and sub-system testing are included under PREOP testing. Factory testing shall be specified in the technical specification section to which it applies and include the required performance for a successful test, method of simulation, and test sheet. Factory testing also shall include timing requirements for fixing a failed test and resuming or aborting and rescheduling factory testing. Performance testing also shall be specified in the technical specification section to which it applies and include the required performance for a successful test, method of simulation, and test sheet. If substantial temporary construction is required to conduct any performance test, that temporary construction shall be detailed on the construction drawings provided in the Contract Documents. Mechanical and HVAC PREOP testing includes: equipment manufacturer s installation and start-up certification, pump and fan functional checkout, sound and vibration tests, air balance test, piping and valve vapor or liquid leakage tests, pipe cleaning, flushing and disinfection tests, and, where required, performance testing of individual equipment (e.g., pump capacity versus total dynamic head). Electrical PREOP testing includes: NETA testing of electrical equipment, conductor and cable tests, motors larger than 50 Hp insulation tests, luminaire switching and receptacle rotation and polarization tests. Control PREOP testing includes: instrument calibration and testing, digital control and logic end-to-end tests, analog loop endto-end tests, and loop tuning. Other PREOP tests included in the Project Technical Specifications include: earthwork and paving compaction tests; concrete and masonry strength tests; coatings thickness tests; tank and structure leakage tests; etc. PREOP and start-up activities associated with the various stages of Work comprising the Project testing shall be detailed by the Design Engineer for inclusion in the Construction Documents (i.e., Specifications). PREOP testing shall be carried out on all mechanical, electrical, and instrumentation and control equipment, and all the associated items including major pipelines, civil structures, and buildings. The PREOP test plans prepared by the Design Engineer must include the following elements where applicable: 1. Review of completed Functional Testing forms to verify that the item to be tested and all associated equipment and appurtenances have successfully completed functional checkout testing. 2. Pre-operation lubrication Sacramento Regional County Sanitation District 4-1 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

12 Project Test Plans Preparation Guide 3. Setting and testing of all protective, control, and auxiliary devices. Required settings and operation of all these devices shall be verified and functionally tested; trip points shall be measured, adjusted, calibrated, and recorded upon both increasing and decreasing process variable. Tests using simulated input or output signals will not be acceptable to satisfy this requirement. Use of input or output signals may be approved by the District s representative if equipment damage would result from using the actual process variable. 4. Equipment shall not be operated prior to the completion of the pre-operational and start-up checkout. The Functional Checkout and Performance Test that are conducted as part of PREOP testing are discussed below. 4.1 Functional Checkout Functional Checkout forms prepared by the Design Engineer must include the following elements where applicable: 1. Every item shall be uniquely tagged per District auto-numbering tagging convention and entered into the District s Asset Management System before Functional Checkout. 2. Every item shall be tested, and the results documented and confirmed, to ensure correct alignment, balancing, and rotation. 3. Every manual and actuated valve shall be tested, and the results documented and confirmed, under normal system conditions to ensure correct operation. This shall include the setting of torque and limit switches where appropriate. 4. Every instrumentation loop shall be tested, and the results documented and confirmed, to ensure correct operation. 5. Every item shall be functionally tested, and the results documented and confirmed, to ensure "Manual Control" and "Remote Automatic Control," and "Automatic Control" functions. 6. Every signal and alarm shall be tested (by simulation if necessary), and the results documented and confirmed, to ensure correct operation. 7. All processes shall be demonstrated, and the results documented and confirmed, to have been erected correctly and adjusted in accordance with the manufacturer s recommendations. An example of a Functional Checkout test form is included in Appendix A. 4.2 Performance Test Performance test forms shall be prepared by the Design Engineer for inclusion in the Construction Documents; the forms shall be located and numbered sequentially with the appropriate equipment specification sections or included per discipline as an appendix to the Sacramento Regional County Sanitation District 4-2 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

13 Project Test Plans Preparation Guide Project Technical Specifications, Section Commissioning. An example of a Performance test form is included in Appendix B. Performance testing of systems shall be conducted in two stages: (1) each individual component shall be performance tested, and (2) after each component has successfully completed performance testing, the system shall be performance tested as a whole. The performance test plans prepared by the Design Engineer, therefore, must confirm the intended performance of individual items of equipment and the entire system as applicable: Performance test procedures must be designed to verify that the equipment and systems meet the intent of the Design Engineer and the manufacturer s performance claims included in the equipment and O&M submittals. Process water, the origin of which (e.g., primary effluent, secondary effluent, filter effluent, etc.) will be identified by the Design Engineer in the Project Test Plans, shall be used for the performance testing of all liquid systems. Excluded from this requirement are gaseous, oil, and chemical systems which will be tested using the intended fluid or a compatible substitute subject to District s approval. Performance test procedures will include the measurement of all operating parameters as specified in the appropriate equipment specification section or in an appendix to the Project Technical Specifications, Section Commissioning. The Design Engineer must identify in the performance test plan the operating parameters to be measured and the criteria that define successful performance. In the Project Test Plans, the Design Engineer must describe the quantities of process water to be used during performance tests, how the process water will be introduced into the system or sub-system being tested, how the process water will be disposed of and how the system or sub-system will be cleaned after the test, and how all of these activities will be coordinated with the District. Equipment shall be operated for a sufficient period of time to observe and record machine operating and performance characteristics including, but not limited to, noise, temperature, and vibration. Key performance characteristics measured during performance testing will be identified during the Reliability Centered Design Workshops conducted with District staff during design. The Design Engineer will identify in the performance test plan specific procedural steps to be taken to verify that all associated control and instrumentation systems function properly under actual operating conditions; tests using simulated input or output signals will not be acceptable to satisfy this requirement. The Design Engineer s performance test plan will include steps to be taken after performance testing to check tested equipment for loose connections, unusual movement, or other indications of improper operating conditions and/or characteristics. Any deficiencies so noted shall be corrected to the satisfaction of the District s representative. Sacramento Regional County Sanitation District 4-3 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

15 Project Test Plans Preparation Guide 5.0 Operational Test Plan Preparation Design Engineer shall prepare Operational Test (OP TEST) Plans to verify that the individual components function together properly as a system using reclaimed water. The Design Engineer s OP TEST Plan will include verification that a District representative has certified that all Installation Tests have been successfully completed and a Certificate of Occupancy, signed by the Consumes Fire District Fire Marshall, has been submitted. The Design Engineer s OP TEST Plan will include steps to be taken to fill all process systems to be tested, except those using domestic water, oil, air, or chemicals, with plant effluent water. All domestic water, oil, air, and chemical systems shall be filled with the specified fluid. Upon completion of the filling operations, the Design Engineer s Operation Test Plan shall describe how the operation test will commence within 12 hours. The OP TEST Plan prepared by the Design Engineer will accommodate the execution in three distinct stages: (1) 48-hour test, (2) 10-day Operational test and (3) 30-day Reliability test. The stages are described below hour Test The 48-hour Test Plan shall be prepared by the Design Engineer for inclusion in the Construction Documents. The 48 hour testing shall be carried out only after successful completion, and documentation of all PREOP testing. The purpose of the 48-hour Test is to circulate water through the completed facility for a period of not less than 48 continuous hours, during which all parts of the system shall be operated as a complete facility at all possible hydraulic loading conditions, as directed by the District and detailed by Design Engineer. The Design Engineer s 48-hour Test Plan will provide a means of documenting and verifying that the Contractor shall operate all equipment during the 48-hour Test while being responsible for performing all preventative maintenance and recording all performance and operational data identified by the Design Engineer. In addition, the 48-hour Test Plan, prepared by the Design Engineer, shall include: 1. Skills requirement for all personnel operating equipment during the 48 hour preoperational testing. 2. Draft Operations and Maintenance requirement for use by Contractor during 48- hour Pre-operational Testing. 3. Schedule for implementing the testing of the overall system performance including accurate flow measurement, accurate flow split, and achieving maximum and minimum design flows. 4. Reference to all report forms required to record all operating parameters for each individual component at each loading condition to be tested. 5. Mechanism for confirming and documenting successful completion of the 48-hour Pre-operational Test An example of a 48-Hour Test Plan and associated forms are included in Appendix C. Sacramento Regional County Sanitation District 5-1 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

16 Project Test Plans Preparation Guide day Operational Test The 10-day Operational Test Plan shall be prepared by the Design Engineer for inclusion in the Construction Documents. Each system must operate at its average design range for 240 consecutive hours under automatic and manual control. The Design Engineer s Operational Test Plan will reflect that the 10-day Operation Test will not begin on Fridays, weekend days, holidays, or on a day before a holiday. The District will operate all equipment and record all data during the 10-day Operational Test. The Contractor will maintain all equipment during this test period. In addition, the Contractor shall provide a minimum of one skilled, experienced equipment start-up specialist, preferably a California certified operator, during dayshift to assist in equipment operation, record data, and troubleshoot problems. The Design Engineer s Operational Test Plan will reflect the fact that this specialist shall be assigned only to this task during this test period. The Operational Test Plans, prepared by the Design Engineer, shall include the following details regarding the 10-day Operational Test: 1. Contractor requirements including the required number of skilled experienced equipment start-up specialists to assist in equipment operation, data recording and troubleshooting during the test period. 2. Training requirements for all District personnel operating equipment during the 10 day-operational testing. 3. Draft Operations and Maintenance Manuals requirement for use by District personnel during 10-day operational testing. 4. Description and method for the diversion of flows into new treatment units. 5. Requirements and set-points for all operational parameters. 6. Compliance checklist for authorization and agreement by the District on diverting wastewater to the new treatment units. 7. Report form to record all operating parameters for the facility. 8. Every equipment item shall be updated with operational and calibration details into the District s Asset Management System. An example of a 10-Day Operational Test Plan and associated forms are included in Appendix D day Reliability Test Plan The 30-day Reliability Test Plan shall be prepared by the Design Engineer for inclusion in the Construction Documents. This 30-day Reliability Test shall be carried out only after successful completion of the 10-day Operational Test. 30-day reliability testing shall not begin until the Engineer notifies the Contractor in writing that all installed and operational tests have been successfully completed. Equipment manufacturer's installation certification forms shall be submitted, prior to the beginning of any reliability tests as specified in this section. Sacramento Regional County Sanitation District 5-2 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

17 Project Test Plans Preparation Guide During the reliability test, all systems shall be operated by District under both maximum and minimum design conditions. The 30-day Reliability Test Plan, prepared by the Design Engineer, shall include: 1. Contractor requirements including the required number of skilled experienced equipment start-up specialists to assist in equipment operation, data recording and troubleshooting during the test period. 2. Training Requirements for all District personnel maintaining equipment during the 30 day-operational testing 3. Final Operations and Maintenance Manuals requirement for use by District personnel during 30-day operational testing 4. Requirements and revised set-points for all operational parameters 5. Report forms to record all operating parameters for the facility 6. Mechanism for referring problems which cannot be resolved on-site to the Engineer and mechanisms for implementing alternatives developed by the Engineer to correct the problems. 7. Requirements for implementing the Performance Test Plans developed and approved previously. 8. Mechanism for updating Operations and Maintenance Manuals with amendments, additions or revisions. An example of a 30-Day Reliability Test Plan and associated forms are included in Appendix E. Sacramento Regional County Sanitation District 5-3 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

19 Project Test Plans Preparation Guide 6.0 Test Plan Examples The District maintains a library of Project Test Plan examples. The Design Engineer may refer to the examples during the preparation of the Project Test Plan specific to the unit processes or modifications to existing facilities for which the Design Engineer is responsible. Sacramento Regional County Sanitation District 6-1 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

21 Project Test Plans Preparation Guide 7.0 Schedule The Project Test Plans shall be prepared by the Design Engineer for inclusion in Design Submittal No. 3 (DS-3) to the District. Also included in DS-3 will be the initial schedule for the implementation of the various test plans. Sacramento Regional County Sanitation District 7-1 Advanced Wastewater Treatment Plant Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test Plans Guide v1.0.docx September 24, 2012

23 APPENDIX A FUNCTIONAL CHECKOUT FORM EXAMPLES

25 APPENDIX A FUNCTIONAL CHECKOUT FORM EQUIPMENT #: CONTRACT # TEST NO: Pump Function Checkout REF. DRAWING # (S) MANUFACTURER: MODEL #: LOCATION: SPECIFICATION #: EQUIPMENT DESCRIPTION: 1.) Verify anchor bolts torque. 2.) Set alignment and balancing Settings A: B: C: 3.) Mechanical seals checked 4.) Mechanical equipment cleaned and flushed 5.) Protective devices set Device Tag# Description Setpoint Remarks WITNESS BLOCK Test Personnel: Contractor Representative: District Representative: Date: Date: Date: A-1

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27 APPENDIX B PERFORMANCE TEST FORM EXAMPLE

29 APPENDIX B PERFORMANCE TEST FORM CONTRACT # 4110 TEST NO: 11312D1: Rotary Lobe Positive Displacement Pumps Performance Test EQUIPMENT #: MANUFACTURER: REF. DRAWING # (S) MODEL: PUMP TYPE: SPECIFICATION #: All pre-operational tests must be performed prior to the performance test. Refer to pump spec and manufacturer data for operating performance data. Provide all appropriate temporary piping and fittings. TEST RESULTS Target Capacity, gpm Actual Capacity, gpm Upstream/ Downstream Head, ft Pressure Loss, psi Motor Speed, rpm Phase Voltage Phase KW Motor Temperature COMMENTS Test Personnel: Contractor Representative: District Representative: WITNESS BLOCK Date: Date: Date: B-1

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31 APPENDIX C 48-HOUR TEST PLAN EXAMPLE

33 CONTRACT #4110 APPENDIX C 48-HOUR TEST PLAN 48-HOUR TEST WITH WATER FOG/FPW Receiving Station Objective: To perform a 48-hour wet test using water on the FOG/FPW Receiving Station to test the strainer, grinder/rock trap, transfer/mixing pump, storage tank, feed pumps, associated valves and piping. Prior to pre-operational testing, make sure that all performance tests are completed. FOG Receiving Equipment 1. Make sure that the strainer, grinder/rock trap, transfer/mixing pumps, storage tanks, feed pumps, and associated valves are READY. The valves isolating the line to the MS lines where the FOG/FPW will be fed should be closed and locked out. 2. Obtain the necessary cam lock connectors and connect a water truck to the offloading connection and use reclaimed water available at the septage receiving station. Use the transfer/mixing pump to automatically configure the valves and pump the water to the storage tank. The pump and valves should switch to mixing mode after each truck load. Multiple truck loads will be required so that the content of the water trucks exceeds the capacity of the storage to observe high alarm and shutdown events. 3. Once the storage tank is full, disconnect the truck and observe the valve operation changing to the mixing configuration. 4. Allow the storage tank to mix with the upper tank discharge point for 3 hours per day and modify the valving to utilize the mid-point discharge for the remainder of the day. 5. Configure the valving to allow the feed pump to operate and fill the second storage tank through one FOG/FPW line to the MS line and back through the other FOG/FPW line. 6. Observe the low level shut off. 7. Drain the content of the tank and repeat the process with the second FOG/FPW storage tank. 8. After completion of the storage tank testing described in steps 1 through 7, drain the content into the drain system. 9. Provide temporary piping water truck and related equipment as needed. C-1

34 CONTRACT #4110 TEST NO. : FOG/FPW Receiving Station 48-Hour Test Report Form Fill out separate form for each piece of equipment being tested. APPENDIX C 48-HOUR TEST PLAN EQUIPMENT #: REF. DRAWING # (S) MANUFACTURER: MODEL: SERIAL #: EQUIPMENT SUBMITTAL #: START OF TEST: END OF TEST: Provide lubrication for equipment as recommended by manufacturer prior to testing. 48-HOUR TEST CHECKLIST Date/Time Description of Test Pass Fail CONTR. INITIALS ENGR S WITNESS COMMENTS C-2

35 APPENDIX D 10-DAY OPERATIONAL TEST PLAN EXAMPLE

37 APPENDIX D 10-DAY OPERATIONAL TEST PLAN CONTRACT # DAY OPERATIONAL TEST WITH FOG FOG/FPW Receiving Station Objective: To perform a 10-day wet test using water on the FOG/FPW Receiving Station to test the strainer, grinder/rock trap, transfer/mixing pump, storage tank, feed pumps, associated valves and piping. Prior to operational testing, make sure that all pre-operational tests are completed. 10-DAY OPERATIONAL TEST PREREQUISITES Date/Time Description of Test Pass Fail CONTR. INITIALS Skilled experienced equipment start-up specialists to assist in equipment operation, data recording and troubleshooting during the test period Training Requirements met for all District personnel operating equipment during the 10 dayoperational testing All operational and calibration characteristics for each item entered into the District Asset Management System Set-points provided for all operational parameters Description and method for the diversion of flows into new treatment units provided Report form to record all operating parameters complete Mechanism for problem resolution prepared Approval by SRCSD Operations for diverting flows ENGR S WITNESS D-1

38 FOG Receiving Equipment APPENDIX D 10-DAY OPERATIONAL TEST PLAN PART ONE 1. Make sure that the strainer, grinder/rock trap, transfer/mixing pumps, storage tanks, feed pumps, and associated valves are READY. The valves isolating the line to the MS lines where the FOG/FPW will be fed should be closed and locked out. 2. Obtain the necessary cam lock connectors and connect a truck (FOG, FPW, or MS) to the offloading connection. Use the transfer/mixing pump to automatically configure the valves and pump the FOG, FPW, or MS to the storage tank. The pump and valves should switch to mixing mode after each truck load. Multiple truck loads will be required so that the content of the trucks exceeds the capacity of the storage to observe high alarm and shutdown events. 3. Once the storage tank is full, disconnect the truck and observe the valve operation changing to the mixing configuration. 4. Allow the storage tank to mix with the upper tank discharge point for 3 hours per day and modify the valving to utilize the mid-point discharge for the remainder of the day. 5. Configure the valving to allow the feed pump to operate and fill the second storage tank through one FOG/FPW line to the MS line and back through the other FOG/FPW line. 6. Observe the low level shut off. 7. Drain the content of the tank and repeat the process with the second FOG/FPW storage tank. 8. After completion of the storage tank testing described in steps 1 through 7, remove locks from the valves to the MS lines, pump content into the operational MS line. 9. Close tank valves and ensure isolation of the FOG/FPW tanks, and test the FOG/FPW flushing with mixed sludge for 3 days. 10. Provide temporary piping, FOG, FPW, or MS truck and related equipment as needed. PART TWO 1. Drain the content of either or both tanks. 2. Implement Control Strategy D-2

39 APPENDIX D 10-DAY OPERATIONAL TEST PLAN CONTRACT #4110 TEST NO. : FOG/FPW Receiving Station 10-Day Operational Test Report Form Fill out separate form for each piece of equipment being tested. EQUIPMENT #: REF. DRAWING # (S) MANUFACTURER: MODEL: SERIAL #: EQUIPMENT SUBMITTAL #: START OF TEST: END OF TEST: Provide lubrication for equipment as recommended by manufacturer prior to testing. 10-DAY OPERATIONAL TEST CHECKLIST Date/Time Description of Test Pass Fail CONTR. INITIALS ENGR S WITNESS COMMENTS D-3

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41 APPENDIX E 30-DAY RELIABILITY TEST PLAN EXAMPLE

43 30-DAY RELIABILITY TEST 01660C7 MIXED SLUDGE FEED SYSTEM GENERAL TEST PLAN APPENDIX E 30-DAY RELIABILITY TEST PLAN The reliability test for the MS feed system consists of placing in service the permanent MS feed control system, each digester battery MS feed pump and associated automatic control system, and MS return sludge flow control system. The District and Engineer will develop and implement a detailed start-up plan to place the permanent mixed sludge feed system in service. The Contractor will be responsible for all preventive and corrective maintenance of all mechanical, electrical and instrumentation equipment, fine tuning instrumentation control loops, and cleanup if due to equipment or piping failure. The temporary MS feed system will be placed out of service and the new MS feed system will be placed in service. The MS feed system includes automatic speed control of all three digester battery MS feed pumps, ratio control of the same MS feed pumps, automatic start;stop of the backup MS transfer pumps, automatic start/stop of the MS booster pumps, automatic speed control of the MS transfer pumps and MS booster pumps, automatic level control of the MS feed tank via the output of all three digester battery MS feed pumps. The MS feed pumps for two batteries will be placed in service in manual flow control. The MS feed pumps for the other battery will be placed in service in automatic ratio flow control. Following fine tuning and verification of automatic operation, the second battery will be placed in service in automatic control and the same for the third battery. Concurrent to sequencing in service the automatic control of the MS feed pumps, the MS transfer pump(s) will be placed in manual speed control and if required the MS booster pump( s). After all three digester battery MS feed pumps have been debugged and readied for the reliability test, the MS transfer pump/ms booster pump return sludge loop shall be placed in service. The MS feed system shall be operated at loading rates as establish by the District. During the reliability test, the Contractor shall put into service each standby MS feed pump to take the place of one duty MS feed pump per Battery II and III digesters. The duration of operation of the standby MS feed pump will be determined by the District. E-1

44 APPENDIX E 30-DAY RELIABILITY TEST PLAN 30-DAY OPERATIONAL TEST PREREQUISITES Date/Time Description of Test Pass Fail CONTR. INITIALS Skilled experienced equipment start-up specialists to assist in equipment operation, data recording and troubleshooting during the test period Training Requirements met for all District personnel maintaining equipment during the 30 day-operational testing Final Operations and Maintenance Manuals requirement for use by District personnel during 30-day operational testing available Revised set-points provided for all operational parameters Report form to record all operating parameters complete Mechanism for problem resolution prepared Mechanism for updating Operations and Maintenance Manuals prepared Approval by SRCSD Operations for starting test ENGR S WITNESS E-2

45 APPENDIX E 30-DAY RELIABILITY TEST PLAN 30-DAY RELIABILITY TEST CHECKLIST Date: Day # of 30 day test: System Items to be Checked Checked By Problems Mixed Sludge Tank 1 Mixed Sludge Tank 2 Primary Sludge Grinder 1 GDR83926 Primary Sludge Grinder 2 GDR83927 Primary Sludge Grinder 3 GDR83928 Mixed Sludge Tank Circulating Pump 2 P83907 Mixed Sludge Tank Grinder 1 GDR83924 Verify Level at LIT & LI Verify High/Low Level Alarms Verify overflow Alarm Verify LIC 8551 Stability Verify LIC 8551 Stpoint/Proc Var Verify Level at LIT & LI Verify High/Low Level Alarms Verify overflow Alarm Verify LIC 8551 Stability Verify LIC 8551 Stpoint/Proc Var Grinder Speed Grinder Amp Verify Local HS Verify ACC HLS Verify Grndr HI Press Alarm Verify Grndr Diff Pres Alarm Verify Grndr Jam Alarm Verify Grndr Jam Shutdown Grinder Speed Grinder Amp Verify Local HS Verify ACC HLS Verify Grndr HI Press Alarm Verify Grndr Diff Pres Alarm Verify Grndr Jam Alarm Verify Grndr Jam Shutdown Grinder Speed Grinder Amp Verify Local HS Verify ACC HLS Verify Grndr HI Press Alarm Verify Grndr Diff Pres Alarm Verify Grndr Jam Alarm Verify Grndr Jam Shutdown Pump Speed Pump Flow Pump Mtr Amp Discharge Press Suction Press seal Water Flow Verify Local HS Verify ACC HLS Grinder Speed Grinder Amp Verify Local HS Verify ACC HLS Verify Grndr HI Press Alarm Verify Grndr Diff Pres Alarm Verify Grndr Jam Alarm Verify Grndr Jam Shutdown E-3

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