Testing of installations in road tunnels.

Testing of installations in road tunnels.

Agenda The Norra Länken-project Presentation of the magnitude of the tests FAT-site with different systems and objects Testing workflow of the Norra Länken-project What can we do be better as clients in our contracts 2 2013-09-24

3 2013-09-24 Norra Länken

Design requirements Norra Länken: Road twin tunnel approx.16 km roads including 11 km road tunnels with19 technical rooms and 50 escape routes The tunnel includes underground on and off access points The tunnel is divided in 22 traffic sections Continuous supervision from Traffic central Tunnel operation includes15 different systems; Electric, Fire, Roadsigns, Tunnelvent, Traffic, Control, Watersupply, SDS, Tele comm. DCS, Control system with approx. 6000 objects or 150.000 tag Dimensioned for queue Fixed Fire Fighting System Fire load: 100 MW Longitudinal tunnel ventilation with jet fans Air supply- and exhaust-stations Very high environmental requirements for tunnel ventilation Traffic flow 100,000 vehicles/day 20% of heavy load vehicles No separate smoke shaft None purification of the air 4 2013-09-24

Contracts installation NL 66 NL 67 NL 68 NL 69 NL72 Electrical systems, control systems, telecommunication systems and traffic systems. Contractor Tunnelentreprenad Jet-Fans for tunnel ventilation. Contractor Bravida Ventilation and electr. installation in substations. Contractor Bravida Waste water and pumps. Contractor Läkeby Water Fixed Fire Fighting System. Contractor Bravida All-in contract / Functional specification 5 2013-09-24

Working process and payment Design. Specifications, Plans, Documentation. Manufacturing Installation Testing (FAT); Component, Own contract, All contracts (NL66-NL67/68/69) Commissioning (SAT); Installation, Function, Continuity check Pilot operation (OAT) Achievement based payment plan Opens for public in nov 2014 6 2013-09-24

NL66 El-, Telecom-, Control-and traffic systems Electrical systems Telecom. Systems Traffic system Control system Other Power supply ink UPS, Tunnel lightning with carriageway lightning. Telephony, Radio, CC-TV, Security, Fire alarm etc. Motorway control, Variable signs, Barriers, Accident and incident detection. Control and monitoring of all technical systems. Interfacing central system in traffic management centre Trafik Stockholm, Doors and hatches, operation and dismantling of temporary installation. Contract Includes: Temporary operation before opening Maintenance 5 years (year 3 to 5 optional) Coordinator for working environment 7 2013-09-24

TALK / DATA TALK RS CS TR RD TD CD d i g i t a l Why is it so complex? Stop Detection of vehicles, an example of communication and functions (LLU/ LLC) Citect I/O Ritn.: XXXYZZZ Citect Alarm SD S - Fu n k t i o n Funktion Internt kablage Profibus - DP Ethernet (GCP) Kamerasignal (Fiber) Beskrivning av funktionssamband mellan olika Teknikområden med kommunikationsgränssnitt åskådliggjorda. Preliminär Dokumenteras av TO.. Global Communication Platform Citect EG TO- Trafik (DU) Ritn.: XXXT4310 Portserver TO-Tele (DU) Ritn.: XXXYZZZ TO- Styr (DU) Ritn.: XXXYZZZ S7- PCMS Internt kabl. S/V Videosignal Traffic Box Video Trak ITV TO-Kraft (DU) Ritn.: XXXYZZZ C UPS Kamera 8 2013-09-24

Factory Acceptans Testing A metod to ensure technical type solutions for client and contractors for turnkey contracts. The importance to understand the written words 9 2013-09-24

My first experiense was at Harman & Braun in Minden. Testing area at Prufeldt for Hässelby Power plant (200MW Electric) in 1992 Testing of on/off objeks Process pictures Start and stop seqences for boiler and turbine Today working with functional demands and testing for the road tunnels and bridges in the Stockholm area for Trafikverket since 2002 Testing of on/off objects Process pictures Start and stop sequences for tunneloperation and road bridges 10 2013-09-24

FAT (Factory Acceptance Test) FAT refers acceptance testing during factory testing, ie, before delivery to and installation in the plant. FAT 1 Factory Testing of standard components and equipments. ** FAT 2 Functional testing of composite components / functional units whose function has adapted and developed according to the project needs, integration tests for the control and monitoring functions for each system. ** FAT 3 Sample of features and functionality related to two operations areas, incl. integration tests with other systems and system tests and performance test. Testing includes verification of signal exchange with systems or components delivered in another contract. ** FAT 4 Tests of the plant's entire functionality incl. verification of operation against Trafik Stockholm (the regional traffic central) real time systems. *** ** The customer and contractor takes part *** Lead by the customer and the contractor takes part 11 2013-09-24

SAT (Site Acceptance Test) SAT refers to testing at the plant site. SAT 1 test of all functions in all technological systems within their operations area. * SAT 2 test of all system functions and functional connection between systems within all operating areas. The test also includes testing of interfaces to systems or components supplied by other contractors. ** SAT 3 Testing the system on plant-wide level incl. performance tests and tests of sequenses for tunnel closing and opening. ** SAT 4 Overall test of the entire plant functionality incl. integration test against the Trafik Stockholm real time systems and verification of the system's functions at predefined event scenarios. *** * The contractor takes part ** The customer and contractor takes part *** Lead by the customer and the contractor takes part 12 2013-09-24

OAT (Operational Acceptance Test) OAT relates trial operation. OAT 1 Before the traffic opening; Trial operation of the installation and operation of the regional systems in Trafik Stockholm. Commissioning and operator training beforetraffic opening. *** OAT 2 after traffic opening; Trial operation of the installation and operation of the regional systems in Trafik Stockholm. Commissioning and operator training for Traffic opening. *** GAT (Guarantee Acceptance Test) GAT intends guarantee test. GAT 1 Follow-up during the warranty period with samples *** *** Lead by the customer and the contractor takes part 13 2013-09-24

The Contractor shall provide a suitable test site for the test facility. The venue will be in Stockholmsregionen. FAT 3 and 4 shall be implemented in a contractor prepared test facility. The test facility shall include at least one item of each type but if several items are necessary to achieve the intended function of the number of items included. Each Contractor shall submit to the test facility, provision of equipment to test the interoperability of equipment delivered in other contracts. 14 2013-09-24

The test facility shall include; Control and monitoring systems for redundant operation areas 1 and 2 and control and monitoring systems for a substation. Equipment in local management center, such as microphone, Fire tableau. All types of central equipment, traffic and telecommunications equipment, and monitors Sensor for control and monitoring in general All types main components such as switchgear, cameras etc included in a substation which shall be controlled and monitored. Control and monitoring systems for the various types of facilities that are provided by sub-contractors. Equipment for the overall test of the entire plant functionality incl integration test against the Trafik Stockholm real time systems and verification of the system's function which also are supplied by the Customer 15 2013-09-24

FAT-workflow The contract includes approximately 3000 claims. Functions and performance requirements The contractor NL66 do the following: Start the planning of the plant parallel to the FAT 1-4 works Establishes System description for all technical systems Establishes System specification for all technical systems with more details, manufacturer, model, performance, etc. Creates Graphical Function Block in the DCS -system* approx. 50-60. Image Building and server configuration (redundancy, load distribution etc. Programming and self-control of function blocks (which is then reused for all hardware controllers) * DCS = Distributed Control System 16 2013-09-24

FAT-workflow cont. Establishes Test Documents, certificates and schedules Establishes control specification with claims and step by step implementation for testing Testing of all type object and systems For example in FAT-3; Action Plans, barriers and shutdown device, lane signals, moving camera, the closing and opening of the tunnel Desktop connectivity for reviewing images All events are stored in web-based log and rated Number of events: FAT 2: no: 157 and FAT-3: no: 190 Major changes after FAT is handled via CCB *and require retesting CCB = Change Control Board 17 2013-09-24

18 2013-09-24 FAT-utr.pdf

Improvements and simplifications One contract for engineering systems Tender document in a turnkey contract, shall consist of thought functional requirements Each technical system with requirements may only consist of 10-15 pages Simple Solutions Standardized solutions Uniformly labeling system Combine FAT-testing with the installed equipment in a early made supply station with switchgear, transformers, telecomm. cabinet control cabinet Use a simulator for tunnel ventilation to get a faster commissioning (Stockholm Bypass) Work with the contractor under the legal and contractual requirements that prevail Make demands on the skills of personnel for similar tunnel projects Make demands on a common control and monitoring technical system with support organization within the region 19 2013-09-24

20 2013-09-24 Demolishing testing (Not in our claims, just for fun)

The Stockholm bypass Length: just over 21 km Tunnel: just over 18 km Tunnel length: approx. 50 km Travel time: approximately 15 minutes No. of lanes: three in each direction Junctions: six Traffic 2035: 140,000 vehicles/day Build start: earliest 2013 Completion: 8-10 years Cost: SEK 27.6 billion EUR 3.1 billion (2009 prices) 21 2013-09-24

Thanks you for your attention. Lars Elertson Specialist control, monitoring and communication. lars.elertson@trafikverket.se Mobil: +46 70 587 67 34 Swedish Transport Administration 22 2013-09-24