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PreCom Guide PDF
PreCom Guide PDF
Version 2.0
(Replaces Project Test Plans Preparation Guide, Version 1.0, September 2012)
September 2013
Commissioning Plan Preparation Guide
Contents
1.0 Introduction ........................................................................................................................................ 1-1
1.1 Purpose ........................................................................................................................................................... 1-1
1.2 Relationship with Other District Design Standards ........................................................................................ 1-1
2.0 Commissioning ................................................................................................................................... 2-1
2.1 General............................................................................................................................................................ 2-1
2.2 Description...................................................................................................................................................... 2-1
2.3 Roles and Responsibilities .............................................................................................................................. 2-3
3.0 Commissioning Plan .......................................................................................................................... 3-1
3.1 Overview ........................................................................................................................................................ 3-3
3.1.1 Data Management System and Document Control ................................................................................. 3-3
3.2 Testing ............................................................................................................................................................ 3-4
3.2.1 Commissioning Team ............................................................................................................................. 3-4
3.2.1.1 Contractor ........................................................................................................................................ 3-4
3.2.1.2 District ............................................................................................................................................. 3-5
3.2.1.3 Design Consultant ........................................................................................................................... 3-5
3.2.2 Pre-Commissioning ................................................................................................................................. 3-5
3.2.2.1 Pre-Commissioning Tests and Tasks ............................................................................................... 3-5
3.2.2.2 Pre-Commissioning Deliverables .................................................................................................. 3-12
3.2.3 Clean Water Commissioning ................................................................................................................ 3-15
3.2.3.1 Functional Acceptance Tests ......................................................................................................... 3-16
3.2.3.2 Performance Acceptance Tests...................................................................................................... 3-19
3.2.4 Startup ................................................................................................................................................... 3-20
3.2.4.1 Reliability Acceptance Tests ......................................................................................................... 3-21
3.2.4.2 Performance Acceptance Tests...................................................................................................... 3-23
3.2.5 Activation .............................................................................................................................................. 3-24
3.3 Training ........................................................................................................................................................ 3-24
3.3.1 General .................................................................................................................................................. 3-24
3.3.2 Content .................................................................................................................................................. 3-25
3.3.2.1 Contractor ...................................................................................................................................... 3-25
3.3.2.2 Design Consultant ......................................................................................................................... 3-25
3.4 Schedule........................................................................................................................................................ 3-25
3.4.1 Commissioning Plan ............................................................................................................................. 3-25
3.4.2 Commissioning Activities ..................................................................................................................... 3-25
Tables
Table 2-1. Commissioning Activities ........................................................................................................................ 2-2
Table 2-2. Design Consultant’s Tasks and Deliverables ........................................................................................... 2-3
Table 2-3. District Construction and Commissioning Tasks ..................................................................................... 2-3
Table 3-1. Commissioning Plan Outline.................................................................................................................... 3-1
Table 3-2. Pre-Commissioning Tests, Tasks, and Responsibilities ........................................................................... 3-6
Table 3-3. Pre-Commissioning Deliverables and Responsibilities .......................................................................... 3-12
Table 3-4. Clean Water Commissioning Tests, Tasks, Deliverables, and Responsibilities ..................................... 3-16
Table 3-5. Functional Acceptance Test Plan Outline .............................................................................................. 3-17
Table 3-6. Startup Tests, Tasks, Deliverables, and Responsibilities ....................................................................... 3-21
Table 3-7. Reliability Acceptance Test Plan Outline ............................................................................................... 3-22
Table 3-8. Activation Tasks, Deliverables, and Responsibilities............................................................................. 3-24
Appendices
Appendix A. Examples of Technical Specifications Tests
Appendix B. Examples of Functional Acceptance Tests
Appendix C. Examples of Reliability Acceptance Tests
Abbreviations
Acronym Description
AR Access Request
BIM Building Information Model
CAD Computer Aided Drafting
CCTV Closed Circuit Television
CM Construction Management
CMMS Computerized Maintenance Management System
CPM Critical Path Method
DS Design Submittal
I/O Input/output
FAT Functional Acceptance Test
FDT Factory Demonstration Test
HMI Human-Machine Interface
HVAC Heating, Ventilation, & Air Conditioning
MCRT Mean Cell Residence Time
MEL Mechanical Equipment List
MMI Maintenance Managed Item
NETA International Electrical Testing Association
NPDES National Pollutant Discharge Elimination System
O&M Operations and Maintenance
OMTG Operator Manual and Training Guide
P&ID Process and Instrumentation Diagrams
PA Public Address
PAT Performance Acceptance Test
PCC Plant Control Center
PCCS Plant Computerized Control System
PLC Programmable Logic Controller
PMO Program Management Office
RAT Reliability Acceptance Test
RCD Reliability-Centered Design
RFI Request for Information
RFP Request for Proposals
RWQCB Regional Water Quality Control Board
SRCSD Sacramento Regional County Sanitation District
VFD Variable Frequency Drive
1.0 Introduction
1.1 Purpose
This document establishes the requirements for the Design Consultant to prepare a
Commissioning Plan for the Sacramento Regional County Sanitation District (District)
EchoWater Project. The Commissioning Plan shall be developed by the Design Consultant in
an effort to plan, organize, and document commissioning activities. Inclusion of the
Commissioning Plan with the Contract Documents shall provide Contractor awareness of the
level of effort the District requires to implement and document equipment and system
preparedness. The Commissioning Plan shall be included as an appendix to the Technical
Specifications (Specifications), Section 01 91 00 – Commissioning.
Due to the magnitude of the EchoWater Project, separate contracts shall be awarded for various
portions of the project. During the project lifecycle, coordination between the various Design
Consultants and District staff will be critical for ensuring cohesion amongst the various
projects’ Commissioning Plans.
be contained in the Request for Proposals (RFP). Particular reference is made to the Reliability-
Centered Design (RCD) process to be implemented on projects involving treatment facilities
and appurtenant equipment.
2.0 Commissioning
2.1 General
Commissioning is the final stage of the project life cycle in which the objective is to validate
the performance of the new equipment/systems/processes per the design intent and the required
service levels of the District. In addition, District staff classroom and field training are provided
by the equipment vendors and the Design Consultant to prepare them to operate and maintain
the facilities.
2.2 Description
Commissioning shall consist of the following stages:
Table 2-3 provides the District’s tasks during the construction and commissioning stages and
identifies the responsible party from the District.
12. Witness and approve HVAC pre- CM 12. Develop final Contractor’s CM/O&M/PMO
operational tests per Specifications. punch list.
13. Witness and approve CM 13. Field accept Contractor’s CM/O&M/PMO
instrumentation calibration tests per punch list.
Specifications.
14. Witness and approve analog loop CM 14. Release Notice of Field CM/O&M
end-to-end testing at PLC and PCCs Acceptance.
per Specifications.
15. Witness and approve analog loop O&M 15. Document commencement of O&M
end-to-end testing at PCCS. warranty period.
16. Witness and approve digital control CM 16. Process optimization. O&M/PMO
and logic end-to-end testing at
PLCs and PCCs per Specifications.
17. Witness and approve digital control O&M 17. Plant wide optimization O&M/PMO
and logic end-to-end testing at
PCCS.
18. Public address system pre- CM
operational tests per Specifications.
19. CCTV system pre-operational tests CM
per Specifications.
20. Fire alarm system pre-operational CM
tests per Specifications.
Through the Commissioning Plan, the Design Consultant prepares detailed test plans and
procedures for commissioning the equipment and systems, and prepares a preliminary schedule
of commissioning test and training activities. Provided in Table 3-1 is an example outline of a
Commissioning Plan for the Design Consultant to use as a reference. The table identifies and
briefly describes the various sections and nominates the responsible party for preparing the
initial content. After notice to proceed, the Contractor shall review, edit, or modify the
Commissioning Plan to account for items such as changes to the construction schedule,
purchased equipment, safety procedures, identification of the commissioning team, etc. The
Contractor must ensure the overall objectives set forth in the commissioning plan are met.
Edits to the Contractor’s commissioning plan shall be reviewed by the Design Consultant and
District O&M/PMO. Final acceptance of the Commissioning Plan shall be provided by the
District to the Contractor.
3.1 Overview
The Design Consultant shall provide an introduction to the Commissioning Plan and a
description of the facility/project. The Contractor shall include a section detailing safety
requirements that must be complied with during commissioning. This shall include, but not be
limited to, quality control and safety procedures, proper personal protective equipment, lock-
out/tag-out procedures, and other District safety requirements.
data, reviewing and approving commissioning test results and deliverables, and ultimately
transferring select data to the District’s Computerized Maintenance Management System
(CMMS).
The Design Consultant shall be responsible for preparing the framework of the commissioning
testing database within PMWeb. This involves identifying the association with an asset-type
(i.e. pump, modulating electric control valve, magnetic flow meter, etc.) and its respective test
activities per the requirements of the Specifications. For example, the associated tests for a
mixed liquor pump shall include: FDT, delivery inspection acceptance, pre-operational tests,
manufacturer’s installation certification, and PATs (mechanical, vibration, and noise) for clean
and process water operating conditions. This database will serve as the starting point for
managing and tracking the flow of data, documents, and testing during commissioning. The
preliminary framework of the database shall be included with Design Submittal No. 2 (DS-2).
The final framework of the database shall be included with DS-3. Prior to construction, assets
(by equipment tag numbers) from the BIM models will be extracted and uploaded to PMWeb
(by the PMO) where the assets will be automatically assigned (based on asset-type) to the
framework of the database. The intent shall be to develop a process within PMWeb where the
selection of an individual asset lists all the associated tests and provides the electronic test
forms for the Contractor to document all the test results.
3.2 Testing
As part of the Commissioning Plan, the Design Consultant shall develop FAT, PAT, and RAT
test plans and procedures. These test plans and procedures detail the coordinated, sequential
testing of each system component and piece of controlled equipment installed under the
Contract. Test plans and procedures shall identify, by system and specific tag number, each
device or control station to be manipulated or observed during the test procedure and the
specific results to be observed or obtained. Test plans also shall be specific as to the support
systems required to complete the test work, temporary systems required during the test work
(including any temporary construction needed for testing), representatives to be present, and
expected test duration.
3.2.1.1 Contractor
The Contractor shall engage a Commissioning Coordinator to be responsible for planning,
coordinating, conducting, and documenting commissioning test activities. The Commissioning
Coordinator shall use a team consisting of representatives of the Contractor’s mechanical,
electrical, and instrumentation subcontractors. The Commissioning Coordinator shall have a
minimum of ten years of experience in operations and commissioning of facilities, equipment,
electrical equipment and plant controls of similar type, size, and capacity, and shall be a
Grade V Operator who is experienced in all aspects of commissioning and testing. The
Commissioning Coordinator and his/her team shall be available during all commissioning
activities at the work site during normal working hours and shall be available within 2 hours’
notice at all other times upon notice by telephone. During the RATs, a Contractor’s
representative shall be on site 24 hours per day. Additional requirements for the Contractor and
the Commissioning Coordinator shall be located in the Commissioning Specification.
3.2.1.2 District
Unless directed otherwise, the District shall have the option to witness all commissioning test
activities for compliance with the Contract requirements. The District CM team shall witness
the majority of the pre-commissioning testing and inspections. The District O&M/PMO team
shall witness the majority of the commissioning (Clean Water Commissioning and Startup)
testing. During Startup and under the supervision of the Commissioning Coordinator, District
O&M staff shall operate the facility, conduct daily rounds, provide sampling and testing,
perform maintenance, and note any abnormal observations. Additional District involvement
prior to and during commissioning is to prepare the PCCS control strategies and facilitate the
Contractor’s end-to-end tests verifying the PCCS end, respectively.
The Design Consultant, with input from the District, shall prepare a preliminary commissioning
organization chart which shall be updated by the Contractor after notice to proceed. The
organization chart shall illustrate the relationship between members of the Design Consultant,
District (CM, O&M, or PMO), and Contractor during commissioning. It shall also identify the
resources from the Contractor and District (CM, O&M, or PMO) to conduct and witness the
testing within the time constraints of the schedule and budget. As noted previously, each test
plan (FAT, PAT, and RAT) shall clearly define the personnel required to perform and witness
each test and the estimated amount of time to complete the test.
3.2.2 Pre-Commissioning
Pre-Commissioning includes pre-operational testing of the completed structural,
mechanical/HVAC, electrical, instrumentation and control systems and concludes with the
Manufacturer’s Installation Certification. The testing verifies that the installed hardware and
software conforms to the requirements of the Specifications and is ready for operation.
anchored, grounded, and, in general, ready for Clean Water Commissioning. At a minimum,
listed and described in Table 3-2 are the required Pre-Commissioning tests and tasks with the
associated Design Consultant and District responsibilities. Contractor responsibilities and scope
of work during construction and commissioning shall be located within the Specifications. The
District’s previous requirements for Pre-Commissioning tests and associated test forms are
referenced from the Specifications and are listed in Appendix A. The Design Consultant shall
provide any additional project-specific equipment test requirements and add/modify the test
forms to suite. In general, the Pre-Commissioning tests and tasks shall be defined in the
Specifications.
17. CCTV system pre-operational Demonstrates the operation of the District CM to witness.
tests CCTV system.
18. Fire alarm system pre- Inspection and acceptance testing District CM to witness.
operational tests shall include a visual inspection of all
fire system components, and a
complete functional test to
demonstrate the operation of each
device following installation.
Tests shall demonstrate that the entire
fire alarm system functions as
intended. All circuits shall be tested:
automatic sprinkler (pre-action),
elevator recall, equipment shutdown
and alarm devices.
19. Fiber optic cable pre-operational Each optical fiber shall be tested for District CM to witness.
tests end-to-end OTDR trace and
attenuation for each installed span
after cable installation.
Electrical Equipment Tests
20. International Electrical Testing Newly-installed power systems tests. District CM to witness.
Association (NETA) tests
21. Conductor tests Continuity and insulation resistance District CM to witness.
measurements shall be made on
conductors. The test specified herein
shall be performed prior to
energizing.
22. Motor pre-operational tests Verify that all fixtures and devices District CM to witness.
operate and are correctly polarized,
that motors have correct rotation, and
that all three-phase receptacles have
correct phase sequence and polarity.
Prior to installation of the equipment, the Contractor shall provide and use lubricating oil,
hydraulic oil, grease and other substances required to clean, blow out, flush, lubricate, and
initially charge the equipment for use per the manufacturer’s recommendations. Equipment
storage, installation, maintenance, and servicing shall be recorded and kept up-to-date by
the Contractor and confirmed by the District CM throughout commissioning. Service
records shall be attached to the equipment for District CM verification of compliance.
Piping System Tests. Process piping and related fittings, gaskets, and seals shall be
hydrostatically tested per the requirements of the Specifications. Pipe test reports shall
be filled out and filed for all sections of piping in the system. After successful
completion of piping system pressure and leakage tests, the piping system shall be
cleaned and flushed per the requirements of the Specifications. District CM shall
witness the piping system pressure and leakage tests and the cleaning and flushing.
Valve Pre-Operational Tests. Per the Specifications, manual valves and control valves
shall be tested to demonstrate proper opening, closure, and proper timing using manual
controls. District CM shall witness the valve pre-operational testing.
HVAC Pre-Operational Tests. The HVAC equipment and control systems shall be
tested to conform to the requirements of the Specifications. After the successful
completion of individual HVAC equipment testing, the complete HVAC system shall
be tested, adjusted, and balanced. District CM shall witness the HVAC pre-operational
testing.
Analog loop end-to-end testing at PLCs, PCCs, and PCCS. Each analog loop shall be
tested as an integrated system. This test shall be designed to verify that indicators or
recorders operate correctly, function modules provide proper signal conditioning,
alarms operate correctly, final elements move in the correct direction, and control trips
cause proper action in interlocking of control circuits. As part of loop testing, every
signal circuit connected to the computer input/output (I/O) terminals shall be tested to
verify that it is properly wired and functions as specified to send or receive signals
from the computer system and its I/O equipment. District CM shall witness loop
testing for the PLCs and PCCs. District O&M shall prepare the PCCS control
strategies and facilitate the Contractor’s end-to-end tests verifying the PCCS end.
Digital control and logic end-to-end testing at PLCs, PCCs, and PCCS. The logic test
verifies the proper operation of each discrete control loop to insure the proper
operation of hand switches, interlocks, solenoid valves, other auxiliary devices, status
lights, and alarms. The controls and logic shall be demonstrated in a step by step
fashion that the discrete circuits and logic operate according to the control strategies.
Discrete inputs shall be tested to verify proper state when the field device is switched
between states. Discrete outputs shall be tested to verify field equipment responds
properly (start, stop, etc.). District CM shall witness digital control and logic testing for
the PLCs and PCCs. District O&M shall prepare the PCCS control strategies and
facilitate the Contractor’s digital control and logic tests verifying the PCCS end.
Public Address System Pre-Operational Tests. After the installation of the public
address system components, the Contractor shall demonstrate the operation of each
speaker and horn for the District CM.
CCTV Pre-Operational Tests. After the installation of the CCTV system components,
the Contractor shall verify the network components, DC power supplies, operability of
the cameras, operability of the existing District digital video recorders, and operability
with the existing District operator workstations. District CM shall witness all CCTV
testing.
Fire Alarm System Pre-Operational Tests. Inspection and acceptance testing shall
include a visual inspection of all fire system components, and a complete functional
test to demonstrate the operation of each device following installation. Tests shall
demonstrate that the entire fire alarm system functions as intended. All circuits shall
be tested: automatic sprinkler (pre-action), elevator recall, equipment shutdown and
alarm devices. District CM shall witness fire alarm system testing.
Fiber Optic Cable Pre-Operational Tests. All fibers shall be tested for breaks,
abnormalities, and overall attenuation characteristics to ensure that the cable system
meets the attenuation specifications. District CM shall witness all testing and final
checkout of the fiber optic system to determine fiber optic cable system acceptability.
Motor Pre-Operational Tests. Pre-operational testing of all devices and control circuits
shall be adjusted and made operative prior to energizing. The testing shall consist of
energizing each control circuit and operating each control, alarm or malfunction device
and each interlock in turn to verify that the specified action occurs. Contractor shall
verify that all fixtures and devices operate and are correctly polarized, that motors have
correct rotation, and that all three-phase receptacles have correct phase sequence and
polarity. Verification may be accomplished by momentarily energizing the motor,
provided that neither the motor nor the driven equipment will be damaged by reverse
operation. District CM shall witness all motor tests.
Since the manufacturer will operate the equipment to certify the installation, addition of clean
water to the facilities shall be organized and conducted prior to the manufacturer’s inspection.
The Commissioning Plan shall include steps taken to fill all tested process systems, except
Sacramento Regional County Sanitation District 3-11
EchoWater Project
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Commissioning Plan Preparation Guide
those using domestic water, oil, air, or chemicals. Domestic water, oil, air, and chemical
systems shall be tested using the intended fluid or a compatible substitute subject to District’s
approval. The Design Consultant must describe the required quality and quantities of clean test
water (reclaimed water is preferred), the procurement and addition of test water into the system
or sub-system, disposal of the test water, procedures for cleaning the system or sub-system after
the test, and coordination of these activities with the District. It shall be required to specify the
estimated amount of time to provide water to fill a tank, drain a tank, and the source of the test
water. The Design Consultant shall also identify all expected temporary construction needs
such as temporary return pumps, temporary power, or other required items in order to facilitate
the testing.
• Equipment Submittals
Equipment submittals include, but are not limited to, product data, shop drawings, test
procedures, test results, annotated PLC program listings, AutoCAD® generated drawings,
samples, requests for substitutions, descriptive data, certificates, methods, schedules,
marked contract drawings and specifications, manufacturer's installation and other
instructions, and miscellaneous work related items. District CM shall be responsible for
distributing the equipment submittals from the Contractor to the District PMO
representative. The District PMO representative shall distribute the equipment submittals to
the Design Consultant and respective District Engineering or O&M stakeholders for
review. The District PMO representative shall also provide a review, consolidate the
comments, and submit to the District CM/Contractor.
After the successful completion of all Pre-Commissioning tests, tasks, and deliverables, the
District CM shall allow the Contractor to proceed to Clean Water Commissioning.
District O&M/PMO shall provide the support to witness, review and approve the FATs and
PATs. The Design Consultant shall conduct District staff training, review test results, and
provide on-call and on-site support when requested by the District. Provided in Table 3-4 are
the associated Clean Water Commissioning tests, tasks, deliverables, and responsibilities.
Table 3-4. Clean Water Commissioning Tests, Tasks, Deliverables, and Responsibilities
Tests/Tasks/Deliverables Description Responsibility
1. FATs Tests involving the operation of Contractor to conduct tests, submit test
hardware and software as an results, and system/component set point
integrated system under clean water lists.
conditions.
District O&M/PMO to witness, review,
and approve test results.
2. Loop tuning Loop tuning shall demonstrate stable District O&M to witness and approve.
operation of the loop under actual
operating conditions. This test shall
include adjustment of closed loop
tuning parameters.
3. PATs Validation of individual equipment Contractor to conduct tests and submit
performance specifications under test results.
clean water conditions.
District O&M/PMO to witness, review,
and approve test results.
4. Maintenance of equipment Ensure proper maintenance of Contractor to perform and document
equipment per manufacturer’s maintenance activities.
instructions.
District CM to confirm.
5. Certificate of Occupancy Approval from the Cosumnes Fire District CM to confirm.
District Fire Marshall to occupy
newly constructed
buildings/structures under their
jurisdiction/permit.
6. Completion of District staff Equipment, system, and process Equipment vendor and Design
training classroom and field training. Consultant provided training.
The Design Consultant shall develop FAT plans detailing the coordinated, sequential testing of
every piece of controlled equipment in each of the identified systems. Provided in Table 3-5 is
an example outline of a FAT plan with examples of FAT procedures provided in Appendix B.
g. Valve, Equipment, and Identify equipment for tested systems and related
Instrumentation Lineup Tables process/support systems.
3. Procedures Provide procedures to test automatic operation and
control and specify acceptance criteria required to
release equipment/systems.
4. Appendix a. System/component set point list Identify settings for equipment (i.e. VFD), key
performance indicators to be tested, and process
control set points list.
b. Issues log Identifies test failures and the corrective actions.
• Overview
Each FAT plan shall begin with an overview section that describes the system, control
strategies, various operating conditions, control modes, and identification of protective
interlocks (local and software). The overview shall also include the notification
requirements for the particular FAT plan.
• Prerequisites
Test prerequisites shall include required support and process systems, type and source of
test media, measurement and test equipment, required temporary piping and equipment
configurations, an equipment lineup table, proper equipment and piping labeling
(temporary labeling at this stage of testing may be considered), and a pre-test walkthrough
that must be completed before conducting the test. Support systems such as power, plant
water, potable water, reclaimed water, and utility air shall be identified and must be ready
for operation and available for use during the test. Related process systems shall be
identified and in some cases shall be run in conjunction with the tested equipment or
systems. When such a condition exists, the FAT procedures identify what steps shall be
taken for preparation and implementation. For some systems, procedures for two or more
FATs shall be run sequentially and/or simultaneously in order to demonstrate overall
process area control strategy interaction and record how each system works in conjunction
with the other. In such a case, the procedures shall clearly walk the testing participants
through the correct FAT and procedure numbers.
Valve, equipment, and instrumentation lineup tables shall be provided for each system test
plan where testing could impact other process or support systems. These systems may be
incomplete or in cases where flow paths or equipment operation must be arranged at other
systems to complete the testing. A pre-test walkthrough shall be conducted to confirm
proper valve position and equipment set-up before the test is started. This walkthrough also
familiarizes testing participants with the systems and allows them to verify proper tagging
and equipment identification.
• Procedures
At a minimum, the test plans shall include staffing for each test identifying roles and
responsibilities and procedures clearly stating or listing test objectives, test descriptions,
acceptance criteria required to release equipment and systems for commissioning, test
forms, and checklists/worksheets to be used to control and document the required tests.
The FAT shall provide step-by-step descriptions of the procedures proposed by the Design
Consultant for the systematic testing of all equipment and systems to duplicate, as closely
as possible, operating conditions described in the Contract Documents.
By the time a system is ready for the FAT, its major equipment shall have already been
checked out during Pre-Commissioning. The FAT shall include testing of the equipment in
REMOTE/AUTOMATIC mode where in some cases more than one piece of equipment
runs together as part of a semi or fully automatic system. The FAT shall demonstrate that
each system and equipment function as required per its related control strategies. Failure
mode scenarios such as equipment, instrument, power, and process failures shall be
simulated to validate the appropriate system response. The control strategies identify which
equipment can run in REMOTE/AUTOMATIC, REMOTE/MANUAL, and/or
LOCAL/MANUAL modes and how the system instrumentation is used in conjunction with
the controls. All operating modes and conditions identified in the control strategies shall be
tested.
Local protective, hard-wired interlocks provided in local control panel relay logic and
software protective interlocks programmed into the PLC and/or PCCS software shall be
identified for each system in the FAT overview section. Each interlock will require being
successfully demonstrated to verify proper function and alarm indication. These interlocks
shall be put in place to shutdown equipment during abnormal conditions to protect the
systems from catastrophic failure and/or the equipment from permanent damage.
• Test Completion
A FAT shall be considered complete after all test procedure activities have been
successfully demonstrated, witnessed, and all testing deficiencies have been resolved and
signed-off by the District. The system/component set point list shall be updated to show
any changes/additions identified during testing. In preparation of the FAT, the Design
Consultant shall include the following information in the system/component set point list:
process control set points to ensure that the system and its equipment function properly and
individual equipment component settings (i.e. VFD settings, key performance indicators)
deemed necessary to prevent damage due to abnormal operation.
the PATs during the FATs and RATs shall be included within the required continuous
operation period.
This testing may require temporary piping or facilities that the Design Consultant shall
design and include with the Contract Documents. The Contractor shall furnish, install,
remove when done, and store temporary piping or facilities on site at a location designated
by the District. Any equipment damaged during testing shall be replaced (at the expense of
the Contractor) unless the equipment is intended only for testing, and not normal operations
after the project is completed. The test piping shall include the following key components:
1. The piping connection shall include a flow metering device. The flow metering device
may be an orifice plate, insertion mag meter, or other device proposed by the
Contractor and accepted by the District/Design Consultant.
2. The piping shall include a throttling valve that creates a backpressure on the pumps to
simulate the full and reduced speed head operating range of the pumps.
3. The piping connection shall include necessary pipeline appurtenances such as air
release and vacuum relief valves, isolation valves, drains, and instrumentation. All
appurtenances shall be coated equivalent to requirements for similar permanent
systems or components.
The PAT test results shall be reviewed by the Design Consultant while the PATs shall be
witnessed and approved by District O&M/PMO. After the successful completion of Clean
Water Commissioning tests, tasks, and District acceptance of deliverables, the District shall
allow the Contractor to proceed to Startup.
3.2.4 Startup
Startup validates the functionality and reliability of the integrated facility operating under
normal process water conditions. The testing includes implementing the RAT plans and
procedures that shall be conducted over a period of time to demonstrate the operational
performance and reliability of the system. Any remaining PLC control narratives, PCCS
control strategies, and loop tuning that were not completed during Clean Water Commissioning
shall be verified during Startup. Since the Startup of the project will be dependent on the
operation of existing and new processes, it will be imperative to coordinate with the District’s
Commissioning Integration Team (to be determined). Provided in Table 3-6 are the associated
Startup tests, tasks, deliverables, and responsibilities.
During the RAT, the Contractor’s Commissioning Coordinator shall supervise the operation
and maintenance, by District O&M, of equipment and systems installed on the project.
Although the Contractor is responsible for the site during Startup, the District is liable for
complying with the effluent discharge license requirements. Process water testing is subject to
National Pollutant Discharge Elimination System (NPDES) discharge limits; however, the
Regional Water Quality Control Board (RWQCB) typically allows an exemption of effluent
limits during Startup. District staff shall consult with the RWQCB to determine the proper
notification process and how specific dates of potential non-compliance are to be determined.
In addition to meeting the discharge license requirements, District O&M staff’s involvement in
the RATs shall provide additional in-the-field training of the equipment and systems and
prepare them for the eventual takeover of the facility during Activation. Provided in Table 3-7
is an example outline of a RAT plan with examples of RAT procedures provided in
Appendix C.
c. Valve, Equipment, and Identify the equipment for the process, related
Instrumentation Lineup Tables process, and support systems.
3. Procedures a. Startup of process Provide procedures to startup the process (i.e.
seeding a biological process, shutdowns and/or ties,
etc.).
b. Contingency plan A plan for critical equipment or system failures
during testing.
4. Appendix a. System/component set point list Identify settings for equipment (i.e. VFD), key
performance indicators to be tested/validated, and
process control set points list.
b. Process control data sheets Operational data collection.
• Overview
Each RAT plan shall begin with an overview section that describes the system to be tested
and notifications for shutdowns and tie-ins.
• Prerequisites
Test prerequisites shall include required support and process systems, an equipment lineup
table, and a pre-test walkthrough that must be completed before conducting the test. Both
support and process systems shall be identified and must be ready for operation and
available for use during the test.
Valve, equipment, and instrumentation lineup tables shall be provided for each system test
plan. A pre-test walkthrough shall be conducted to confirm proper valve position and
equipment set-up before the test is started.
• Procedures
The Design Consultant shall prepare a RAT plan to include process control data sheets for
recording operational data and any shutdown and/or tie-in procedures (provide reference to
affected existing systems and/or concurrent designs in progress). During the testing, the
system shall be operated within design parameters reflecting the day-to-day operation of
the facilities, including extreme design conditions (maximum and minimum) for a
continuous period of a minimum of 30 days. Facilities shall be operated with process fluids
at all achievable operating conditions.
If the RAT involves a biological process, then a process acclimation period of three Mean
Cell Residence Time (MCRT) cycles (Design Consultant to advise), followed by 30
continuous days of operation under design conditions without significant interruption shall
be completed. The plan shall include procedures and schedules to seed the process and
build the biology to design conditions, requirements for temporary equipment, and
coordination with District O&M staff. The Contractor shall be responsible for ensuring
the equipment and systems are performing per the requirements of the contract documents.
The Design Consultant shall be responsible for meeting the process requirements per the
design intent.
Contingency Plan. Driven by the RCD process of assessing the criticality of assets and
failure modes, a contingency plan shall provide strategies to mitigate the impacts of
system failures during Startup. As previously mentioned, process water testing is
subject to the NPDES discharge limits; thus, measures shall be taken to mitigate the
risks of violating the regulatory license.
• Test Completion
The Contractor shall request that the District sign-off on the RAT plan to verify a
successful test. For comparison to the FATs and the Specifications, the system/component
set point list shall be updated to show any changes/additions identified during testing.
After the successful completion of Startup tests, tasks, and District acceptance of deliverables,
the District shall release a Notice of Substantial Completion allowing the Contractor to proceed
to Activation.
3.2.5 Activation
Activation indicates the completion of Startup activities with the Contractor relinquishing
control of the operations and maintenance of the facility to the District. This stage of
commissioning includes completion of the Contractor’s final punch list, the beginning of the
guarantee/warranty period, optimizing the process, and plant wide optimization. After the
completion and District acceptance of the punch list, the Contractor may request a Notice of
Field Acceptance that confirms the completion of contract requirements and the beginning of
the guarantee/warranty period.
The Design Consultant shall continue to provide engineering support services for plant
optimization and to ensure the process is meeting the performance requirements as per the
design intent. Provided in Table 3-8 are the associated Activation tasks, deliverables, and
responsibilities.
3.3 Training
3.3.1 General
The Contractor and Design Consultant shall provide on-the-job training of District personnel
for the operation and maintenance of equipment, systems, and processes installed under the
Contract Documents. Prior to training, formal written lesson plans shall be prepared for each
type of training session and shall include the subject of each training session, time allocation
for each subject, identity and qualifications of individuals conducting the training, number and
length of training sessions to cover the course, tentative date, and time of each training session.
Lesson plans shall contain an outline of the material to be presented along with a description of
visual aids to be used during the session. Each training session shall be comprised of time spent
both in the classroom and at the specific location of the subject equipment, system, or process.
The vendors/Design Consultant shall sign and submit waivers prior to the training sessions that
allow the training to be videotaped.
Included within the Specifications, the Design Consultant shall provide the number and length
of training sessions for the individual equipment items. Preliminary training scheduling
information shall be provided along with all other commissioning activities in the baseline
schedule. The Design Consultant shall consult with O&M staff managers regarding availability
of staff for training, number of sessions, shifts, etc. This information will be required in the
Specifications for individual pieces of equipment and shall serve as the Contractor’s scope of
works for training requirements. The Design Consultant shall then prepare an overall training
schedule with individual O&M manual approvals as predecessors. For additional training
requirements, refer to the Specifications, Section 01 79 10 – Training.
3.3.2 Content
3.3.2.1 Contractor
The Contractor shall require the equipment vendors to provide District staff training on the
operation and maintenance of the equipment at the Contractor’s expense. The intent of training
shall be to use the equipment O&M manuals as the principle basis for instruction.
3.4 Schedule
3.4.1 Commissioning Plan
The Design Consultant shall submit a detailed and project-specific outline of the
Commissioning Plan as part of DS-1. The Draft Commissioning Plan shall be included as part
of DS-2, along with a Commissioning Plan Workshop organized and facilitated by the Design
Consultant. The Draft Final Commissioning Plan must address and incorporate comments from
the Workshop and the review process prior to submitting as part of DS-3. Comments from DS-
3 shall be incorporated into the Bid Set and subsequently included in the Contract Documents
as an appendix to the Specifications, Section 01 91 00 – Commissioning.
The preliminary schedule shall be initially prepared with the knowledge that specific dates will
change as construction progresses. After notice to proceed, it shall be the responsibility of the
Contractor to submit an up-to-date schedule. During commissioning, the Contractor shall
ensure this schedule is kept updated and to provide the District daily and three-week look-
ahead schedules. The District shall maintain a master schedule of all shutdowns, tie-ins and
access requests to ensure, first and foremost, that permit compliance is maintained at all times
during construction and commissioning and second, that commissioning progresses according
to the program schedule.
APPENDIX A
EXAMPLES
APPENDIX A
General
Specification Title of Test
Varies Factory Demonstration Test
01 65 00 Delivery Inspection/Acceptance Test
Varies Pre-Operation and Startup Summary Test
Varies Pump Performance Test (Motors < 10 hp)
Varies Pump Performance Test (Motors > 10 hp)
Varies Pump Performance Test (Metering Pumps)
Varies Equipment Vibration Test
Varies Equipment Noise Test
Varies Instruction Certificate Form
Structural / Mechanical
Specification Title of Test
03 30 00 Water Tightness Test – Tanks and Channels
Varies Pump Functional Checkout
26 05 00 Motor Data Form
40 05 96 Sluice Gate Leakage Test
40 05 13 Piping System Pressure and Leakage Test
40 05 13 Piping System Cleaning and Flushing
40 05 64 Butterfly Valve Leakage Test
40 05 64 Butterfly Valve Performance Test
40 05 57 Valve Operators Pre-Operational Test
23 30 00 HVAC Equipment Pre-Operational Test
23 73 00 Air Handling Unit Performance Test
23 09 33 HVAC Control System Pre-Operational Test
23 05 93 HVAC System Testing, Adjusting and Balancing (TAB)
26 42 00 Galvanic Anode Cathodic Commissioning Test
26 42 00 Impressed Current Cathodic Commissioning Test
Electrical
Specification Title of Test
26 05 21 Wire and Cable Continuity/Insulation Resistance Test
26 05 21 Equipment Insulation Resistance Test
26 05 00 Installed Motor Data Test
26 08 10 NETA testing requirements
Instrumentation
Specification Title of Test
26 05 21 Loop Wiring and Insulation Resistance Test
40 61 13-A Test Equipment Calibration Form
40 61 13-B Configurable Analog Control Station Calibration Test
40 61 13-C Indicator Calibration Test
APPENDIX A
Location:
Manufacturer: Model:
Procedures: All preoperational tests must be performed prior to performance test. Refer to applicable specification section and manufacturer data for operating performance
requirements; attach all manufacturer performance data. Any temporary piping shall be installed per specification XXXXXX.
Target Capacity, Actual Pressure Upstream Downstream Head, Motor Speed Power Read Motor Temperature
GPM Capacity, Loss, Head, Ft RPM KW A B C D
GPM PSI Ft Total
7/22/2013 #####-1
SRWTP
CONTRACT # xxxx
SACRAMENTO REGIONAL WASTEWATER TREATMENT PLANT
EchoWater Project
PUMP PERFORMANCE TEST # #####D2 (MOTOR>10HP)
Test No.:________________________________________________________________________________________________________________
Pump Type:__________________________________________________________________________________ Subnet:_____________________
Specification Section Reference:__________________________________________________________________ Date:______________________
Equipment No.:___________________________________________________________________________________________________________
Location:________________________________________________________________________________________________________________
Manufacturer:____________________________________________________________________________________________________________
Model:__________________________________________________________________________________________________________________
Procedures: All preoperational tests must be performed prior to performance test. Refer to applicable specification section and manufacturer data for operating performance
requirements; attach all manufacturer performance data. Any temporary piping shall be installed per specification 01660 and the Operational Testing procedures.
7/22/2013 #####D2-1
SRWTP
PUMP PERFORMANCE TEST (MOTOR >10 HP)
TEST NUMBER: PUMP EQUIPMENT NUMBER: TEST DATE: WATER TEMP: AMBIENT TEMP:
GUARANTEED PUMP CONDITIONS DIM TO DATUM: CL OF SUCT PIPE: CL SUCT GAGE: CL DISC GAGE::
PPM GPM TDH % EFF NPSH SPGR SUCT GAGE RANGE AND ACCURACY: DISC GAGE RANGE AND ACCURACY:
LIST VALVES, PIPE CHANGES, ETC. BETWEEN PUMP AND GAGES:
MOTOR NAMEPLATE DATE PIPE SIZE PIPE LENGTH GAGE TO PUMP FLOW METER
Make Serial No. Frame Volts Amps Rpm HP Type Suct: Suct: Type:
Disc: Disc: Accuracy:
Suct Head (1) Disc Head (2) Power Measurements Temperature Readings
Press El Frict. TDH
Diff Diff Head in ft %
Feet Feet ft gage Ft H20 Watt Elec Eff
Cap. PSG/ of PSIG/ of H20 Cent. H20 2-1 H20 HP Mtr Pwr HP (7/8)
No. GPM in Hg H20 in Hg H20 (2-1) Ft (3) (4) +3+4 (7) KW Volts Amps Factr (8) *100 Mtr Erg Midft Pump Brgs
1
2
3
4
5
6
7
8
PUMP DATA: PUMP MODEL:
Impeller Diameter: PUMP SERIAL NUMBER:
Impeller Pattern: PUMP SIZE:
CONDITIONAL NOTES:
TESTED BY: WITNESSED BY:
TITLE: TITLE:
DATE: DATE:
7/22/2013 #####D2-2
SRWTP
APPENDIX B
APPENDIX B
EXAMPLES
APPENDIX B
1.1 OVERVIEW
A. The purpose of the Functional Acceptance Test (FAT) is to demonstrate to the District that both
the software and hardware installed under this Contract is performing as specified. The test is
performed with the equipment in service using plant water (secondary effluent). The FAT is a
combined effort between the District and the CONTRACTOR. The tests will require coordination
with Operations to ensure normal processing is not disrupted. An District maintenance person
should be present when flow is sent to other facilities in the Plant.
B. Each DAFT tank will be fully commissioned from start to finish, (IAT, FAT, and RAT), before
proceeding to the next DAFT. This schedule will be based on work sequencing as discussed in
the Contract Documents.
Part 1 Saturation System. This test will check proper operation of all saturation
system equipment, including the back pressure control valve, recycle pumps, air
control panels, compressors and all associated valves and interlocks.
Part 2 Feed Sludge System. This test will check proper operation of the influent
sludge system valves, including flowmeters and all associated valves and
interlocks.
Part 3 DAFT Collection Equipment. This test will check proper operation of the
collector unit equipment, including the DAFT drive unit mechanism, bottom
sludge and float collector arms, underflow system comprising the underflow weirs
and gates and all associated valves and interlocks.
Part 4 Thickened Sludge System. This test will check proper operation of the TWAS
pumps, thickened sludge discharge force main flowmeter, including all
associated valves, level controls and interlocks.
Test Procedure
Sign-off/
# Test and Setup Required Results
Comments
19 Test Saturation Tank Drain Cycle, typical for all tanks while
pumping as follows:
At the FCP, place the MOV OCR selector in the CLOSE At SCADA, verify
position, valve closed. Closed status - ON
At the FCP, place the OCR selector in the OPEN position, At SCADA, verify
valve opens. Opened status - ON
At the FCP, place the OCR selector in the REMOTE At SCADA, verify
position, valve closes. Remote status - ON
At SCADA, verify
Simulate MOV fail to open when called by SCADA.
Fail - ON
At SCADA, verify
Simulate MOV fail to close when called by SCADA.
Fail - ON
At SCADA, verify
Simulate valve trouble at MOV.
Trouble - ON
Test Procedure
Sign-off/
# Test and Setup Required Results
Comments
Test Procedure
Sign-off/
# Test and Setup Required Results
Comments
At VFD, run the motor in Hand and simulate High Torque Verify motor does not
stop.
At SCADA - verify
High Torque - ON
At VFD, run the motor in Hand and simulate Over Torque Verify motor stopped.
At SCADA - verify
Over Torque - ON
Remove simulation of alarm condition. Verify that drive does
not restart
At VFD, place HOR selector in Off Position. Press Reset At SCADA - verify
Pushbutton. alarm is - OFF
At VFD, simulate Motor High Temperature Verify motor stopped.
At VFD, run the motor in Hand longer than VFD timer At SCADA - verify
setting Motor High
Temperature - ON
Remove simulation of alarm condition. Verify that drive does
not restart
At VFD, place HOR selector in Off Position. Press Reset At SCADA - verify
Pushbutton. alarm is - OFF
Test Procedure
Sign-off/
# Test and Setup Required Results
Comments
Verify liquid from
1 Test the operation of DAFT A TWAS Telescoping Valve
(22ITSV815), typical for all DAFTs, through its full range of
the DAFT tank is
motion via the motorized actuator. Follow additional testing discharged through
protocol as follows: the valve when in
the low position.
At the FCP, place the MOV LOR selector in the LOCAL At SCADA, verify %
position, close valve with CLOSE pushbutton. Opened – 0%
At the FCP, place the LOR selector in the position, open At SCADA, verify %
valve with OPEN pushbutton. Opened – 100%
At the FCP, place the LOR selector in the REMOTE At SCADA, verify
position. Remote status - ON
At SCADA, verify %
Set SCADA to call valve to open to 50%.
Opened – 50%
At SCADA, verify
Simulate MOV fail to open when called by SCADA.
Fail - ON
At SCADA, verify
Simulate MOV fail to close when called by SCADA.
Fail - ON
At SCADA, verify
Simulate MOV open for an extended period of time.
Open Time Warning
- ON
At SCADA, verify
Simulate valve trouble at MOV.
Trouble - ON
SCADA operates
Remove simulated alarms.
MOV to 50%.
SCADA operates
At SCADA, set telescopic valve open start, cycle period,
MOV based on time,
duration, and position setpoints. Put valve in Automatic.
cycle, duration, and
position setpoints.
2 Verify operation of the DAFT A TWAS Sump bubbler
control panel (22IFCP819), typical for all DAFTs, with the
following procedures:
SCADA, verify Low
Bubbler air supply turned off.
Air Pressure - ON
Open air supply valve, FCP instrument valves, close drain
valve, set pressure regulator, and set rotameter air flow.
Verify bubbler level
DAFT TWAS Sump filling in process.
reading matches
SCADA reading
SCADA, verify High
Fill DAFT TWAS Sump past High Level.
Level - ON
SCADA, verify
At SCADA, set purge cycle frequency and duration time,
DAFT level remains
and initiate bubbler purge sequence.
steady during purge.
At bubbler, verify
purge sequence
closes level
At SCADA, enter pump lead start, lag start, and stop DAFT
Sump level setpoint, put pump in Automatic.
At SCADA, put telescoping valve in Manual and adjust to SCADA starts lead
vary DAFT Sump level above lead start setpoint. pump.
At SCADA, adjust telescoping valve in Manual to vary SCADA starts lag
DAFT Sump level above lag start setpoint. pump.
At SCADA, adjust telescoping valve in Manual to vary SCADA stops both
DAFT Sump level below stop setpoint. pumps.
At SCADA, put telescoping valve in Manual and adjust to SCADA starts lead
vary DAFT Sump level above lead start setpoint. pump.
Simulate pump failure for running pump. SCADA starts the
other pump.
Remove simulated pump failure.
After all eight DAFT TWAS pumps have been tested, put all Verify that under no
6
in Remote, and in Automatic at SCADA. Sequentially conditions will
adjust DAFT telescoping valves to raise sump level above SCADA operate
Test Procedure
Sign-off/
# Test and Setup Required Results
Comments
1 Turn off feeder breaker for DAFT MCC at switchgear Monitor to confirm
SWGR-BC that status signals
from the DAFT
system are available
at the SCADA
powered by the UPS
1.1 OVERVIEW
A. The purpose of the Functional Acceptance Test (FAT) is to demonstrate to the District that
both the software and hardware installed under this Contract is performing as specified. The
test is performed with the equipment in service using clean water only. The FAT is a
combined effort between the District and the CONTRACTOR. The tests will require
coordination with Operations to ensure normal processing is not disrupted. A District
maintenance person should be present when flow is sent to or drawn from other facilities in
the Plant.
B. Digesters will be tested sequentially, starting with Digester I. Once Digester I testing is
completed, digester test water will be transferred to Digester J.
1.2 TEST PROTOCOL
A. The combined software/hardware system is tested from this point forward. The test is
performed with equipment in service under normal operating conditions, and extreme design
conditions (max and min), to the extent that test conditions allow. The purpose of the test is to
ensure that the PLC and Operator Graphics software configuration is working in conjunction
with the hardware and plant as intended.
B. Equipment will operate with plant water. Application software problems encountered during
the test will be investigated and corrected by the CONTRACTOR. Problems with PLC and/or
PCCS software programming done by the District, will be corrected by the District. The
CONTRACTOR shall provide a qualified person familiar with the installation and trouble-
shooting of PLC panels, working full time, under the direction of the Commissioning
Coordinator, for the duration of the test. Prior to the test the CONTRACTOR shall submit a
written FAT procedure, prepared by the Commissioning Coordinator, to the District for
approval. The District’s approval of the procedure prior to the start of the FAT is required.
C. The CONTRACTOR shall include in its schedule four work days per calendar week and 40
hours per work week to troubleshoot each PLC in the Digester I,J,K Electrical Room. PLC
tests shall not overlap in the schedule, except with written permission of District’s PCI
division.
D. Alarm/Interlock Simulation testing shall be completed prior to Test Procedure. Reference
Alarm/Interlock Simulation Table for Details.
E. Reference Test Procedure below for Digester System for details. Equipment shall be
installed tested in accordance with Section 01450, the General Requirements and the
following.
1.3 COMPONENTS
Part 0 Digester Preparation. Prior to testing, the CONTRACTOR shall install
temporary flow meter and piping and shall fill the digester will plant water.
Part 1 Digester Feed System. This system will NOT be tested in the clean water FAT.
This test will check proper operation of the digester feed equipment including
influent valves and level monitoring as part of the RAT.
Part 2 Digester Heating and Recirculation System. This test will check proper
operation of all Heating and Recirculation equipment, including the heat
exchanger, hot water pump, recirculation pump, grinder, and all associated
valves and interlocks.
Part 4 Digester Booster Pump. This system will NOT be tested in the clean water
FAT. This test will check proper operation of the booster pumps and all
associated valves during the RAT.
Part 5 Digester Transfer Pump. This test will check proper operation of the transfer
pumps, flow meter, and all associated valves.
Part 6 Power Loss Simulation. This test will check backup power comes online
successfully and that all system components reset themselves and come back
online ready for operation.
1.4 TEST PROCEDURE
A. Following is a general procedure for conducting the FAT for Digester I. Similar FAT will be
conducted for Digester J process areas.
B. Part 0: Prepare Digester for Functional Acceptance Test
1. Set up Flow Meter. The CONTRACTOR shall prepare for testing of the digester by
setting up a temporary digester inflow & outflow meter, as follows
a. Attach to the emergency overflow pipe from the Overflow Box, which extends to
ground level a temporary vertical 3 inch pipe, just above finished grade with a
temporary flow meter and data recorder supported so that the meter will flow full at
all times.
b. Extend temporary 3-inch pipe from the temporary water meter to plant drain manhole,
immediately northeast of the Ella and Scott Tunnels intersection.
c. Support or brace temporary piping to prevent movement during testing.
2. Fill the Digester
a. Close the following valves:
(1) Steam Cleaning Waste Valves (FV507)
(2) Transfer Header Valve (FV545)
(3) Transfer Pump Discharge Valve (PV580D)
(4) Bottom Sludge Line (FV553)
(5) Recirculation Discharge Valve (PV578)
(6) Recirculation Bypass to J Valve (PV576)
(7) Primary Sludge Feed Valve Digester I (FV 500)
(8) TWAS Feed Valve (FV509)
(9) Ferric Feed Valve (BV516C)
(10)PV519 and PV819 (digester-to-Overflow Box high and low valves)
b. Open the following valves:
(1) Digester Gas Vent through Carbon Canister valves (top of digester dome) fully
open to permit air displaced by water to vent
(2) Plant Water valves (FV703, FV704, PV542A, PV542B)
(3) Digester Overflow Box Valve PV520
Sacramento Regional County Sanitation District
EchoWater Project
Solids Thickening and Processing Upgrades FAT - DIGESTERS-2
c. Fill the Digester with plant water, until water fills the Overflow Box and begins to
overflow through the overflow pipe downcomer and through the temporary meter.
d. Close the following valves: Plant Water valves (FV703, FV704, PV542A, PV542B)
e. Purge air from mixing pump discharge, open valves PV544D and PV543D, close
once water starts to come through the valve
f. Purge air from transfer pump discharge, open valves PV580C close once water
starts to come through the valve
g. Purge air from recirculation pump discharge, open valves PV919B and PV917B,
close once water starts to come through the valve
h. Purge air from overflow pump discharge, open valves PV555A, close once water
starts to come through the valve
C. Part 1: Digester Feed System - The Digester Feed System will not be tested as part of the
digester FAT.
D. Part 2: Digester Heating and Recirculation System
a. Open isolation valve on the pump suction piping and allow hot water to flow through
the hot water pump and spiral heat exchanger
b. Start the hot water pump
c. Set the digested sludge temperature one degree above the water in temperature.
d. Allow the hot water system to reach equilibrium with the temperature set point 0.5
degrees above the initial sludge out temperature.
e. Start the grinder
f. Start the recirculation pump
g. Adjust the temperature set point at TSC12A
h. Verify that new temperature set point has been received at TSC12C and that valve
TV 564 adjusts accordingly
i. Stop Hot Water Pump and Recirculation Pump
E. Part 3: Digester Mixing System
1. Start Plant Water Flow Through Digester
a. Test Digester I Mixing Pump 1
(1) Open valves FV540, PV453C
(2) Open valve PV542A (plant water)
(3) Start Digester I Mixing Pump 1 (25BPMP543)
(4) Verify mixing pump operates without vibration or cavitation.
(5) Verify the digester is filling such that the Overflow Box is full and water spills into
the overflow pipe downcomer to ground level, thence through the temporary
water meter.
b. Test Digester I Mixing Pump 2 (similar to above for Pump 1)
c. Leave one of the Mixing Pumps running for the Digester Mixing Performance Test
2. Digester Mixing Performance Test (Using Lithium Chloride Tracer)
a. Identify all sample locations and prepare sample bottles.
b. Prepare lithium chloride solution for injection, including Contractor-supplied pump.
c. Manually adjust the position of PV542A until the steady state flow into the digester
(as shown on temporary flow meter) indicates 55 gpm (plus or minus 3 gpm) of plant
water at the temporary water meter.
Test Procedure
Test Procedure
Test Procedure
Test Procedure
Test Procedure
APPENDIX C
EXAMPLES
APPENDIX C
Following completion of the FAT, the CONTRACTOR shall be allowed to proceed with the Reliability
Acceptance Test (RAT) phase of testing.
DAFT C will be the first DAFT to undergo a RAT and the duration will be 45 days, for each
subsequent DAFT a 21 day RAT will be required. CONTRACTOR shall be required to
perform all work described under the RAT phase of commissioning for the number of days
specified above, or until successful completion of the continuous 7 day operation
requirement, whichever is longer. Monitoring requirements and schedule for the 7 day
continuous operating test are specified at the end of this RAT document.
If process acclimation and the 7 days of continuous operation requirement are completed in
less than 21 or 45 calendar days, duration depending on which DAFT is undergoing the RAT,
CONTRACTOR shall continue with work described under the RAT phase for the full duration
of the calendar period.
If the process acclimation and the 7 days of continuous operation requirement is not
completed after full duration of the calendar period, CONTRACTOR shall continue to perform
all work described under the RAT phase until the RAT has been accepted as complete, with
no limit on the time period required to complete the RAT, and with no additional
compensation.
Reliability Acceptance Test (RAT) shall be performed on behalf of the CONTRACTOR by the
Commissioning Coordinator after the FAT is completed and accepted.
Constraints: To the extent practical, during the RAT the plant shall be operated at average dry weather
flow conditions during night time hours, and all abnormal, maximum and minimum flow conditions shall be
tested during daylight hours.
Procedure: The DAFT sludge feed consists of waste sludge (WS), scum (S), and waste activated sludge
(WAS). The sludge feed system must be operational before the DAFT process can be started. Each
DAFT tank will be fully commissioned from start to finish before proceeding to the next DAFT. This
schedule will be based on work sequencing as discussed in the Contract Documents.
The DAFT tank will be filled with secondary effluent to prepare for the startup. The water will be back fed
from the secondary effluent piping into the pressurization piping as shown on the Contract Drawings. This
will require the normally closed secondary effluent valve to be opened and all recycle pump suction
valves to be closed. The secondary effluent will fill the recycle sumps and back feed into the submerged
launder filling the DAFT tank. The water level should be maintained by the underflow weir gate located in
the underflow box. The secondary effluent valve will be shut off once a DAFT liquid level elevation of
11.5’ has been reached.
Once the water level is maintained and the SE valve is shut off, one (1) saturation system consisting of a
recycle pump and saturation tank will be started. A summary of the startup procedure is as follows.
Detailed steps can be found in the startup activities table below.
All monitoring points (flows, pressures, etc.) should be checked and recorded on RAT daily process
control data sheets by the CONTRACTOR during the commissioning period.
Prior to initiation of testing as specified on log sheets CONTRACTOR shall set up and perform a valve
checklist to ensure equipment is ready to be tested. Checklist shall verify all procedures in the startup
activity table have been performed.
Startup Activity
Verify all required operational tests of mechanical and electrical systems have been
1. successfully performed.
Ensure the following slide gates and valves are in the proper position for operation of
2. DAFT before startup:
A. DAFT feed sludge valves closed
B. Back Pressure valve (on top of DAFT tank) unit fully open
C. Recycle pump suction and discharge valves closed
D. Underflow box effluent gate is open
Verify all valves are closed on the TWAS, saturation system, and polymer piping.
3.
4.
Start polymer batching of the permanent polymer system if polymer commissioning has
been completed. Otherwise use the temporary polymer system for the purpose of
conducting the DAFT RAT:
Note: Contractor shall test the polymer feed pumps and corresponding flowmeters per
Polymer RAT requirements during the corresponding DAFT RAT if not already done so
during the Polymer RAT.
5. Open SE valve and recycle sump isolation valve in order to back feed SE from
pressurization piping into the submerged launder and fill DAFT tank
6. Startup the DAFT collector mechanism at 50% of full speed
7. Verify the water level is maintained by the automated underflow weir in the underflow box
9. Ensure polymer feed flow is flow paced based on the influent solids loading
10. Set polymer dilution water flow to 10 gpm on the pump skid rotameter
11. Open/Close valves as necessary to route the combined WAS/WS feed sludge to the
DAFTs
13. Open TWAS pump suction and discharge valves. Startup the TWAS pump once float
begins to collect in the TWAS sump if not already set in Auto mode
14. Begin sampling and monitoring the process control parameters (described in RAT
Process Control Data Sheets) every 3-4 hours for the duration of the commissioning
period.
1. Starting on Day 1 operate the DAFT at the annual average combined sludge flow of 1.54
MGD. Continue operating at this flow for all of Days 2, and 7 along with the night-shifts of
Days 3, 4, 5, and 6. Flow adjustments can be achieved by throttling the motorized DAFT feed
valve via CRISP. The entire DAFT system shall be performance tested by the Contractor to
ensure correct operation as one complete functioning unit, including all DAFT related mechanical
and electrical systems not limited to liquid and solids pumps, sludge collection systems, underflow
gates, saturation systems, polymer systems, and foul air systems.
2. Float is collected from the DAFT tank liquid surface by the rotating DAFT basin sweep. The
DAFT basin sweep is rotated in the DAFT tank by a variable speed drive. By adjusting the
speed of the basin sweep and/or the run duration and frequency of the sweep operation the
operator may control how quickly the float is removed from the DAFT tank water surface and
therefore the thickness of the float layer. Basin sweep operation in combination with other
aspects of the process such as polymer dosage and water level are used to optimize the
DAFT operation Control Strategy: The DAFT basin sweep speed and run duration is selected
by the operator to obtain the desired sludge thickness. It is expected that a changes in DAFT
drive speed and run duration would be made only when there are significant changes in
sludge flow. Verify all system components are functioning properly in both local and remote
modes of operation.
3. The recycle pump corresponding to the DAFT system being tested shall be operated across a
range of flows after the initial saturation system adjustments are made as described above.
Standby recycle pumps designed to feed the DAFT being commissioned shall also be tested
for no less than 25% of the time during the 7 day continuous operating test. The recycle
pumps have been selected for a design flow of 1,344 gpm to provide a saturation tank
pressure of 70 psig. Higher tank pressures and hence lower recycle flows can be achieved by
gradually closing the back pressure valve if this is desired for producing better sludge
thickening capabilities. The same principal applies to reducing saturation tank pressure which
is achieved by gradually opening the back pressure valve and fully opening all isolation valves
in the system. Saturation tank pressures should be operated between 65 and 75 psig to find
optimum sludge thickening conditions. Once the optimum setting has been found the recycle
pumps should be held at a constant flowrate and pressure while keeping as close as possible
to the pump’s best efficiency point, as determined by the selected pump curve. Peak air flow
into the saturation system is designed for 45 scfm. This parameter shall be adjusted via the air
control panel to provide the necessary air saturation. Verify all components of the saturation
system are functioning properly in both local and remote modes of operation.
4. The lead and lag TWAS pumps corresponding to the DAFT system being tested shall be run
based on the preset control strategy programmed into the PLC. The lead pump will start after
the level in the TWAS sump reaches a predetermined setpoint. The TWAS pumps are positive
displacement constant speed units each with a capacity of 345 gpm. For the purpose of the
RAT each of the two pumps corresponding to the DAFT being commissioned will be tested to
verify proper operation and flow capacity. This may require alternating the lead and lag
designations of each pump to ensure adequate testing of each unit. In addition, one pump
each from two TWAS sumps (two pumps total) shall be operated concurrently to monitor flow
and pressure performance under maximum flow conditions. This shall take place during DAFT
B commissioning with TWAS Pump B1 or B2 and TWAS Pump C1 or C2 and during DAFT D
commissioning with TWAS Pump D1 or D2 and TWAS Pump A1 or A2.
TSS samples will be collected and used to calibrate the TSS meters and process control.
CONTRACTOR shall have TSS meter rep on site to calibrate TSS meters.
Issue Date Sent Description Action By Finish Evaluation and Action Comments Date
No. Received By By Complete
Lab Analysis
Required
Activity Comments
Day
Mon Tues Wed Thurs Fri Sat Sun YES/NO
RAT LOG SHEETS
Sampling and monitoring of the process control parameters (described below) should take place every 3‐4 hours for the duration
of the entire testing period and recorded on log sheets during the test.
A. Sludge Feed flowrate – Recorded from the DAFT
influent sludge meters.
____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm NO
B. Sludge Feed TSS – Sample from the WAS feed
piping. ____ ____ ____ ____ ____ ____ ____
mg/L mg/L mg/L mg/L mg/L mg/L mg/L YES
C. Sludge Feed TSS – Sample from the TSS meter.
____ ____ ____ ____ ____ ____ ____
mg/L mg/L mg/L mg/L mg/L mg/L mg/L NO
D. TWAS %TS – Sample taken from sample port near
mag meter. ____ ____ ____ ____ ____ ____ ____
% % % % % % % YES
E. Underflow TSS – Sample from pressurization
pump ____ ____ ____ ____ ____ ____ ____
mg/L mg/L mg/L mg/L mg/L mg/L mg/L YES
F. Sludge Blanket Thickness – Measure with sludge
judge or adapted Raven probe (preferred) ____ ____ ____ ____ ____ ____ ____
in in in in in in in NO
G. Polymer dosage rate ‐ lbs of polymer per dry ton
• Expected average = 7, maximum
of solids ____ ____ ____ ____ ____ ____ ____
= 14
lb/dt lb/dt lb/dt lb/dt lb/dt lb/dt lb/dt NO
Also, the following parameters should be calculated from the data collected and recorded on the log sheets:
Lab Analysis
Required
Activity Comments
Day
Mon Tues Wed Thurs Fri Sat Sun YES/NO
RAT LOG SHEETS
Based on the anticipated average
and peak WAS concentrations and
flows, the following are anticipated
process conditions with one DAFT
A. Hydraulic Loading ‐ Calcuated tank on‐line:
____ ____ ____ ____ ____ ____ ____ • Hydraulic loading ~0.9 – 1.2
gpm/ft2 gpm/ft2 gpm/ft2 gpm/ft2 gpm/ft2 gpm/ft2 gpm/ft2 gpm/ft2 NO
____ ____ ____ ____ ____ ____ ____ • Pressurized flow ~ 953 – 1,430
gpm gpm gpm gpm gpm gpm gpm gpm NO
• Combined WAS Concentration ~
____ ____ ____ ____ ____ ____ ____ 3,300 mg/L ‐ 3,700 mg/L
mg/L mg/L mg/L mg/L mg/L mg/L mg/L NO
B. Solids Loading ‐ Calculated
____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm • WAS Flow ~ 1,069 ‐ 1,409 gpm NO
Starting on Day 1 operate the DAFT at the annual average combined sludge flow of 1.54 MGD. Continue operating at this flow
for Days 2 and 7 along with the night‐shift for Days 3, 4, 5, and 6. Flow adjustments can be achieved by throttling the motorized
DAFT feed valve via CRISP.
1. Feed Sludge System
Lab Analysis
Required
Activity Comments
Day
Mon Tues Wed Thurs Fri Sat Sun YES/NO
RAT LOG SHEETS
2. DAFT Sweep
3. Recycle Pump
4. TWAS Pumps
A. Select a lead pump
B. Set level in the TWAS sump
C. Verify the pump starts
D. Record TWAS Pump Flow ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm NO
E. Switch Lead Pump
F. Verify the pump starts
G. Record TWAS Pump Flow ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm NO
Lab Analysis
Required
Activity Comments
Day
Mon Tues Wed Thurs Fri Sat Sun YES/NO
RAT LOG SHEETS
5. Underflow weir gate
The day‐shift of Days 3, 4, 5, and 6 the DAFT will be operated at design peak day flow of 2.03 MGD. Repeat test conditions
1. Feed Sludge System
2. DAFT Sweep
Lab Analysis
Required
Activity Comments
Day
Mon Tues Wed Thurs Fri Sat Sun YES/NO
RAT LOG SHEETS
3. Recycle Pump
4. TWAS Pumps
A. Select a lead pump
B. Set level in the TWAS sump
C. Verify the pump starts
D. Record TWAS Pump Flow ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm NO
E. Switch Lead Pump
F. Verify the pump starts
G. Record TWAS Pump Flow ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm NO
5. Underflow weir gate
Following completion of the FAT, the CONTRACTOR shall be allowed to proceed with the Reliability
Acceptance Test (RAT) phase of testing.
1. For each digester CONTRACTOR shall be required to perform all work described under
the RAT phase of commissioning for a total of 45 days, or until successful completion of
20 days of continuous Active Mode operation requirement and 10 days of Holding Mode
operation, whichever is longer.
a. If the 20-day continuous Active Mode operation requirement and the 10-day Holding
Mode requirement are completed in less than 45 calendar days, CONTRACTOR
shall continue with work described under the RAT phase until the 45 calendar day
period is completed.
b. If the continuous operation requirements for a digester are not completed after 45
calendar days, CONTRACTOR shall continue to perform all work described under
the RAT phase until the RAT has been accepted as complete, with no limit on the
time period required to complete the RAT for that digester, and with no additional
compensation.
Reliability Acceptance Test (RAT) shall be performed on behalf of the CONTRACTOR by the
Commissioning Coordinator for a digester after the FAT for that digester is completed and accepted.
Assumption(s): Plant staff will oversee the transfer of sludge from one of the operating digesters to
the digester that is undergoing the RAT. The text below assumes that Digester I will be the first to
undergo its Active Mode RAT then content of Digester I transferred to Digester J for its Active Mode
RAT. The Digester I Holding Mode RAT can proceed concurrently with the Digester J Active Mode
RAT.
Constraints: During the RAT the plant shall be operated at average flow conditions during night time
hours, and all abnormal, maximum and minimum flow conditions shall be tested during daylight
hours.
Procedure: The Digester RAT will be in two parts for each digester. The first set of tests will be for
Active Mode and the second for Holding Mode.
Active Mode. The digester will be filled with digested sludge by District staff, then normal feeding of
sludge will begin the RAT. Active Mode digester overflows are passive. The digester sludge feed
consists of Primary Sludge (PS) and Thickened Waste Activated sludge (TWAS). At least two DAFTs
must be operational before the digester Active Mode RAT can be started.
Holding Mode. The digester will be fed using the Booster Pump installed in this project. Transfer
from the Holding Mode digester to the dewatering process will be done via the Transfer Pump(s).
General. District staff will fill the digester with sludge from an operational digester to prepare for the
Active Mode startup. This will occur over a two week period following completion of that digester’s
Sacramento Regional County Sanitation District
EchoWater Project
Solids Thickening and Processing Upgrades RAT - DIGESTERS-1
FAT. Following this period the CONTRACTOR will take responsibility of the digester for the duration
of the RAT, for both Active and Holding Mode.
Once the digester is filled, the Active Mode startup procedure can commence. One (1) digester
system in Active Mode consists of digester feed, heating / recirculation, and mixing. In the Holding
Mode, the recirculation pump and hot water pump will be inactive and the booster pump and transfer
pump will be employed.
Detailed Startup steps are shown in the table below. All monitoring points (flows, pressures, etc.)
should be checked during this startup sequence.
4. Fill the Digester with sludge until sludge appears in the sludge overflow box.
8. Open isolation valve on the pump suction piping and allow hot water to flow through the
hot water pump and spiral heat exchanger
9. Start the hot water pump
10. Allow the hot water system to reach equilibrium with the temperature set points
14. Verify that new temperature set point has been received at TSC12C and that valve TV
564 adjusts accordingly
15. Startup Digester I Mixing Pump 1
A. Open valves FV540, PV453C
B. Open valve PV542A (plant water)
C. Start Digester I Mixing Pump 1 (25BPMP543)
D. Verify mixing pump operates without vibration or cavitation.
E. Stop Mixing Pump 1
Repeat procedure with Digester I Mixing Pump 2
16. Leave one of the Mixing pumps running
1. Starting on Day 1 of the 20-day Active Mode RAT operate the Digester I in Active Mode.
Check the following:
a. Record the suction and discharge pressure gages for the following pumps:
i. Recirculation pump
ii. Mixing pump
b. Record the following temperatures at the Heat Exchanger
i. Sludge In (into Heat Exchanger)
ii. Sludge Out (out of Heat Exchanger)
iii. Hot Water In (into Heat Exchanger)
iv. Hot Water Out (out of Heat Exchanger)
c. Record the position of the 3 way valve
10-Day Holding Mode Test: Once the 20-day Active Mode RAT has been completed, the 10-
Day Holding test for Digester I may begin.
Issue Date Sent Description Action By Finish Evaluation and Action Comments Date
No. Received By By Complete
Day
Activity Comments
Mon Tues Wed Thurs Fri Sat Sun
RAT LOG SHEET
1. ACTIVE MODE
‐ Record Level in Digester I ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐ Record Suction Pressure of the Recirculation ____ ____ ____ ____ ____ ____ ____
Pump PSI PSI PSI PSI PSI PSI PSI
‐ Record Discharge Pressure of the Recirculation ____ ____ ____ ____ ____ ____ ____
Pump PSI PSI PSI PSI PSI PSI PSI
‐ Record Heat Exchanger Temperature
‐Record Temperature of Sludge In (Into Heat ____ ____ ____ ____ ____ ____ ____
Exchanger) deg F deg F deg F deg F deg F deg F deg F
‐Record Temperature of Sludge Out (Out of ____ ____ ____ ____ ____ ____ ____
the Heat Exchanger) deg F deg F deg F deg F deg F deg F deg F
‐Record Temperature of Hot Water In (Into ____ ____ ____ ____ ____ ____ ____
the Heat Exchanger) deg F deg F deg F deg F deg F deg F deg F
‐Record Temperature of Hot Water Out (Out ____ ____ ____ ____ ____ ____ ____
of the Heat Exchanger) deg F deg F deg F deg F deg F deg F deg F
‐ Record Suction Pressure of Mixing Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Discharge Pressure of Mixing Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Position of the Three Way Valve ____ ____ ____ ____ ____ ____ ____
2. TRANSFER MODE
‐ Record Level in Digester I ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐ Record Level in Digester J ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
3. Run the Transfer Pump at 50%
‐ Record Speed of Transfer Pump ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm
Day
Activity Comments
Mon Tues Wed Thurs Fri Sat Sun
RAT LOG SHEET
‐Record the flow meter ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm
‐ Record Suction Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Discharge Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Level in Digester I ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐ Record Level in Digester J ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
3. Run the Transfer Pump at 100%
‐ Record Speed of Transfer Pump at 100% ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm
‐Record the flow meter ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm
‐ Record Suction Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Discharge Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Level in Digester I ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐ Record Level in Digester J ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
4. Run the Transfer Pump at 100% until it starts to
cavitate
‐ Record Speed of Transfer Pump at Cavitation ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm
‐Record the flow meter ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm
‐ Record Suction Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Discharge Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
Sacramento Regional County Sanitation District
EchoWater Project
Solids Thickening and Processing Upgrades RAT - DIGESTERS-2
RAT ‐ DIGESTERS I AND J
LOG SHEET
Day
Activity Comments
Mon Tues Wed Thurs Fri Sat Sun
RAT LOG SHEET
‐ Record Level in Digester I ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐ Record Level in Digester J ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
5. Reduce speed until cavitation ceases
‐ Record Speed of Transfer Pump ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm
‐Record the flow meter ____ ____ ____ ____ ____ ____ ____
gpm gpm gpm gpm gpm gpm gpm
‐ Record Suction Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Discharge Pressure of Transfer Pump ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐ Record Level in Digester I ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐ Record Level in Digester J ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
6. Start Booster Pump to empty the remainder of
Digester I
‐ Record Speed of Booster Pump ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm
‐ Record Level in Digester J ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
7. HOLDING MODE
‐ Record the following for the Booster Pump
‐ Record the Following for the Booster Pump
‐Record the Speed ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm
‐Record the Suction Pressure ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
Day
Activity Comments
Mon Tues Wed Thurs Fri Sat Sun
RAT LOG SHEET
‐Record the Level in Digester D ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐Record the Level in Digester G ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐Record the Level in Digester L ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐Record the Level in Digester P ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐Record the Discharge Pressure ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐Start the Transfer Pump, so that is runs based on
the dewatering header pressure, Record the
following:
‐Record the Speed ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm
‐Record the Suction Pressure ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐Record the Level in Digester I ____ ____ ____ ____ ____ ____ ____
ft ft ft ft ft ft ft
‐Record the Dewatering Header Pressure ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐Record the Discharge Pressure ____ ____ ____ ____ ____ ____ ____
PSI PSI PSI PSI PSI PSI PSI
‐Vary the elevation set point in Digester D,G, L and
P, Record the following:
‐Record the Booster Pump Speed ____ ____ ____ ____ ____ ____ ____
rpm rpm rpm rpm rpm rpm rpm