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Commissioning Plan Preparation Guide
Sacramento Regional County Sanitation District

Version 2.0
(Replaces Project Test Plans Preparation Guide, Version 1.0, September 2012)

September 2013

Sacramento Regional County Sanitation District i
EchoWater Project
Z:\00. Program Management\B4.01 - Engineering Standards Update\02 Work Products Archive\B4.01.01 - Commissioning Plan Preparation Guide\Version 2\Commissioning Plan
Preparation Guide_v2.0.docx October 23, 2013
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 Consultants 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

Sacramento Regional County Sanitation District ii
EchoWater Project
Appendices
Appendix A. Examples of Technical Specifications Tests
Appendix B. Examples of Functional Acceptance Tests
Appendix C. Examples of Reliability Acceptance Tests

Sacramento Regional County Sanitation District iii
EchoWater Project
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

Sacramento Regional County Sanitation District 1-1
EchoWater Project
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.
1.2 Relationship with Other District Design Standards
This document is one in a suite of District Design Standards (Standards). These Standards are
created and maintained to provide consistency and efficiency among design projects within the
District. The Standards clearly document requirements, issues, decisions, products, procedures,
etc., that have been widely agreed upon by District staff. The documents comprising the
Standards include:
Design Contract Requirements Presents the content requirements for contract
documents prepared for design projects.
Design Guidelines Describes discipline-specific District design preferences above
and beyond applicable codes and standards.
Guide Specifications A library of technical specifications available for project use.
CAD and BIM Standards Standards to be used on computer aided drafting (CAD)
drawings and Building Information Model (BIM) requirements for data and file
management.
Standard Drawings and Typical Details A library of CAD drawings and typically
used details common across all projects available for use by the Designer.
Operator Manual and Training Guide Development Describes the level of effort
the District requires of the Design Consultant to develop an Operator Manual and
Training Guide (OMTG) specific to their respective project. The OMTG shall be used
as a teaching and reference tool for the Design Consultants portion of the training
courses.
Additional requirements related to execution of the design, project deliverables, and designer
coordination with the EchoWater Program Management Office (PMO) and District staff shall
EchoWater Project
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.
EchoWater Project
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:
Pre-Commissioning: Includes pre-operational testing of the completed structural,
mechanical/HVAC, electrical, instrumentation and control systems as defined in the
Specifications. Pre-operational testing includes activities such as structural leakage
tests, cycling valves, pipe system pressure and leakage tests, instrument calibration, loop
testing, control and logic testing, NETA tests, manufacturer installation certifications,
etc. The objective of Pre-Commissioning shall be to confirm the equipments readiness
to operate as a system.
Clean Water Commissioning: Functional acceptance testing of the hardware and
software to verify all PLC control narratives, PCCS control strategies, and interaction
with other new or existing systems. In conjunction with the system testing, loops shall
be tuned to obtain the desired process control response and individual equipment
performance tests shall be conducted to confirm operational parameters as defined in the
Specifications. District staff training from the Contractor and Design Consultant is also
provided during this stage.
Startup: Reliability acceptance testing of the integrated facility to demonstrate the
continuous and reliable operation of the equipment and systems under normal process
water conditions. This stage includes shutdowns and tie-ins to the existing plant
processes, seeding the biological process (if required), process optimization, additional
loop tuning, and individual equipment performance tests requiring process water.
Activation: Initiated after granting the Contractor substantial completion. District O&M
staff assumes control of the facility/site and the warranty period begins after releasing
Notice of Field Acceptance to the Contractor. This stage includes completion of the
Contractors punch list items, process optimization, and plant wide optimization.
Each stage of commissioning must be completed, witnessed, and documented to the satisfaction
of the District before initiating the next stage of commissioning. At the minimum, the
commissioning stages and associated tests, tasks, and deliverables are presented in Table 2-1.
EchoWater Project
Table 2-1. Commissioning Activities
Construction/Pre-Commissioning
Clean Water
Commissioning
Startup Activation
1. Equipment submittals received and
approved
1. Functional
Acceptance Tests
(FAT)
1. Reliability
Acceptance Tests
(RAT)
1. Contractors punch
list completed and
field accepted
2. Equipment performance guarantees
and warranty letters received and
approved
2. Verification of all
PLC control
narratives and
PCCS control
strategies
2. Verification of
remaining PLC
control narratives
and PCCS control
strategies
2. District Notice of
Field Acceptance
3. RFIs and responses up-to-date 3. Loop tuning 3. Contd loop tuning 3. Commencement of
warranty period
4. Equipment O&M manuals received
and approved
4. Clean water
equipment
Performance
Acceptance Tests
(PAT)
4. Process water
equipment PATs
4. Process
optimization

5. Factory Demonstration Tests (FDT) 5. Certificate of
Occupancy
received
5. Maintenance of
equipment
5. Plant wide
optimization
6. Delivery Acceptance Inspections 6. District staff
training
6. Site clean-up
7. Storage and maintenance of equipment 7. Maintenance of
equipment
7. District field
inspection
8. Verification of installed assets per
design database
8. Final Contractors
punch list
9. Structural tank leakage tests per
Specifications
9. District Notice of
Substantial
Completion
10. Mechanical equipment pre-operational
tests per Specifications (equipment,
valves, HVAC)

11. Piping systempressure and leakage
tests and pipe cleaning/flushing per
Specifications
12. Instrumentation equipment pre-
operational tests per Specifications
(instrument calibration, loops, PLC and
PCCS controls and logic, public
address system, CCTV system, fire
alarmsystem, and fiber optic cables)
13. Electrical equipment pre-operational
tests per Specifications (NETA,
conductors, and motors)
14. Equipment manufacturers installation
certifications
15. Contractors edits to Commissioning
Plan received and approved
16. Design Consultants draft and final
Operator Manual and Training Guide
(OMTG) received and approved
17. Record CAD drawings and BIM
models (includes Master Equipment
List [MEL] and Maintenance Managed
Items [MMI] design database) received
and approved
18. Equipment vendors and Design
Consultants training lesson plans and
course schedules received and
approved
EchoWater Project
2.3 Roles and Responsibilities
Preparation of the Commissioning Plan, followed by the implementation and witnessing of
construction/Pre-commissioning and commissioning test activities shall be a collaborative
effort by representatives from the Design Consultant, Contractor, and District. Table 2-2
provides a list, at the minimum, of the Design Consultants tasks and deliverables during the
design, construction, and commissioning project phases.
Table 2-2. Design Consultants Tasks and Deliverables
Design Construction/Pre-Commissioning
Clean Water Commissioning,
Startup, & Activation
1. Submit design CAD
drawings and BIM
models (includes
MEL/MMI design
database)
1. Review equipment submittals

1. Engineering support services
(i.e. review of test results, on-
call and on-site support, and
process optimization)
2. Review equipment performance guarantees and
warranty letters
2. Submit Specifications 3. Respond to RFIs 2. Conduct required training
courses
3. Submit Project Design
Manual
4. Review equipment O&M manuals
4. Submit Commissioning
Plan
5. Review FDT results
6. Review Contractors edits to Commissioning
Plan
7. Submit Draft and Final OMTG
8. Prepare and submit training course lesson plans
and training materials
9. Review the Contractors training course lesson
plans and training materials
10. Maintain and update record CAD drawings and
BIM models throughout construction (via
Contractor red-lines, District approved
equipment submittals, and District CM
documentation)

Table 2-3 provides the Districts tasks during the construction and commissioning stages and
identifies the responsible party from the District.
Table 2-3. District Construction and Commissioning Tasks
Construction/Pre-Commissioning Clean Water Commissioning, Startup, & Activation
Task
District Responsibility
Task
District
Responsibility
1. Review and approve equipment
submittals, performance guarantees,
and warranty letters.
Engineering/PMO 1. Witness, review, and approve
Functional Acceptance Tests
(FAT).
O&M/PMO
2. Review and approve equipment
O&M manuals.
Engineering/O&M/PMO 2. Witness, review, and approve
verification of all PLC control
narratives and PCCS control
strategies.
O&M/PMO

3. Review and approve RFIs and
responses.
loop tuning.
O&M/PMO
EchoWater Project
Task
Task
District
Responsibility
4. Witness, review, and approve FDT
results.
clean and process water
equipment Performance
Acceptance Tests (PAT).
O&M/PMO
5. Witness Delivery Acceptance
Inspections.
CM 5. ConfirmCertificate of
Occupancy fromCosumnes
Fire District Fire Marshall.
CM
6. ConfirmSpecification requirements
for the storage and maintenance of
equipment by the Contractor.
CM 6. Receive Design Consultant
and Contractor training.
O&M/PMO
7. Verification of installed assets per
design database.
CM 7. ConfirmSpecification
requirements for the
maintenance of equipment by
the Contractor throughout each
stage.
CM
8. Witness and approve structural tank
leakage tests per Specifications.
CM 8. Witness, review, and approve
Reliability Acceptance Tests
(RAT).
O&M/PMO
9. Witness and approve mechanical
equipment pre-operational tests per
Specifications.
CM

9. ConfirmContractor site clean-
up

CM

10. Witness and approve piping
systems pressure and leakage tests
and piping systemcleaning/flushing
per Specifications.
CM 10. Conduct field inspection.

CM/O&M/PMO

11. Witness and approve valve pre-
operational tests per Specifications.

CM

11. Release Notice of Substantial
Completion to Contractor.
CM/O&M
12. Witness and approve HVAC pre-
CM 12. Develop final Contractors
punch list.
CM/O&M/PMO
13. Witness and approve
instrumentation calibration tests per
Specifications.
CM 13. Field accept Contractors
punch list.
CM/O&M/PMO
14. Witness and approve analog loop
end-to-end testing at PLC and PCCs
per Specifications.
CM 14. Release Notice of Field
Acceptance.
CM/O&M
15. Witness and approve analog loop
end-to-end testing at PCCS.
O&M 15. Document commencement of
warranty period.
O&M
16. Witness and approve digital control
and logic end-to-end testing at
PLCs and PCCs per Specifications.
CM 16. Process optimization. O&M/PMO
17. Witness and approve digital control
and logic end-to-end testing at
PCCS.
O&M 17. Plant wide optimization O&M/PMO
18. Public address systempre-
CM
19. CCTV systempre-operational tests
per Specifications.
CM
20. Fire alarmsystempre-operational
tests per Specifications.
CM
EchoWater Project
Task
Task
District
Responsibility
21. Fiber optic cable pre-operational
CM
22. Witness and approve NETA tests
per Specifications.
CM
23. Witness and approve conductor
CM
24. Witness and approve motor pre-
CM
25. Witness equipment manufacturers
installation certifications.
CM
26. Review and approve Contractors
edits to Commissioning Plan.
O&M/PMO
27. Review and approve Draft and
Final OMTG.
O&M/PMO
28. Review and approve training course
lesson plans and training materials.
O&M/PMO
29. Review and approve record CAD
drawings and BIM models (includes
MEL/MMI design database) based
on Contractor red-lines.
Engineering/O&M/PMO


EchoWater Project
3.0 Commissioning Plan
The Commissioning Plan shall include the requirements for planning, scheduling, coordinating,
executing, and documenting Pre-Commissioning, Clean Water Commissioning, Startup, and
Activation activities. The main objective of the Commissioning Plan is to provide an organized
and thorough approach to the validation of the equipment, systems, and processes to be
completed by the Contractor.
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 Contractors 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.
Table 3-1. Commissioning Plan Outline
Heading Section Subsection Description Responsibility
1. Overview a. Introduction A brief introduction to the
Commissioning Plan describing the
overall intent and objectives.
Design
Consultant
b. Overview of the project A brief description of the
facility/project.
c. Safety i. Quality control and
safety procedures
Contractor to provide safety related
documentation.
Contractor
ii. Proper personal
protective equipment
iii. Lock-out/Tag-out
procedures
iv. Other District safety
requirements
d. Data management systemand document control Prepare the framework of a database
to manage and document test
activities associated with each asset.
Design
Consultant
2. Testing a. Commissioning Team Prepare a preliminary organization
chart illustrating the relationship
between the design consultant,
District, construction management
(CM) team, and contractor during
commissioning.
(Note that the District will prepare
the PCCS control strategies and
facilitate the Contractors end-to-
end tests verifying the PCCS end.)

Design
Consultant/
District

EchoWater Project
b. Pre-Commissioning i. Introduction Provide a description of the Pre-
Commissioning tests, tasks,
deliverables, and responsibilities.
Design
Consultant
ii. Pre-Commissioning
Tests
Since these tests shall already be
developed and included in the
Specifications, this section shall
provide a description of any
specialized tests requiring extensive
design development (i.e. complex
subsystemPLC factory test that
requires simulated outputs, mixer
dye testing, large tank leakage test,
etc.) Acceptance criteria for a
successful test shall also be
provided.
c. Clean Water
Commissioning
i. Introduction Provide a description of the Clean
Water Commissioning tests, tasks,
deliverables, and responsibilities.
ii. FATs Provide a description of the FAT,
followed by each FAT test plan and
procedures.
Each FAT test plan shall identify the
required resources, prerequisites,
and acceptance criteria.
iii. PATs Provide a description of the
equipment PAT, followed by a list
of equipment (with equipment
numbers) requiring clean water
PATs and then each PAT test plan
and procedures.
Each PAT test plan shall identify the
required resources, acceptance
criteria, and test forms.
d. Startup i. Introduction Provide a description of the Startup
tests, tasks, deliverables, and
responsibilities.
i. RATs Provide a description of the RAT,
followed by each RAT test plan and
procedures.
Each RAT test plan shall identify
the required resources, prerequisites,
and acceptance criteria.
ii. PATs Provide a description of the
equipment PAT, followed by a list
of equipment (with equipment
numbers) requiring process water
PATs and then each PAT test plan
and procedures.
Each PAT test plan shall identify the
required resources, acceptance
criteria (i.e. mechanical and process
related, if required), and test forms.
e. Activation Provide a description of the
Activation tasks, deliverables, and
responsibilities.

EchoWater Project
3. Training a. Contractor training courses For training requirements, refer to
the Specifications, Section 01 79 10
Training.
Provide a description of the training
requirements and a table of
Contractor (equipment vendor)
required training courses with
number of sessions and duration of
each session as per the requirements
of the Specifications.
The Contractor shall submit formal
lesson plans prior to Clean Water
Commissioning.
Design
Consultant to
identify
Contractor and
Design
Consultant
required
training
sessions.
b. Design Consultant training courses Provide a description of the training
requirements and a table of number
of sessions and duration of each
session as per the requirements of
the Specifications.
The Design Consultant shall submit
formal lesson plans prior to Clean
Water Commissioning.
4. Schedule a. Introduction i. Up-to-date schedules Provide a description of the
Contractors schedule requirements
during commissioning.

Design
Consultant
ii. Three-week look-
ahead schedules
iii. Daily schedules
iv. Master schedule of
access requests (ARs),
shutdowns, and tie-ins
b. Initial commissioning baseline schedule Prepare a preliminary schedule of
commissioning test and training
activities. This schedule shall be
consistent with the Design
Consultants construction operations
sequencing plan.
Design
Consultant

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.
3.1.1 Data Management System and Document Control
The Districts PMO shall be responsible for maintaining a data management and document
control system (PMWeb) for commissioning activities. This includes the collection of test
plans, procedures, test forms, checklists, worksheets, and test results required for and resulting
from commissioning test activities. The objective of this system is to provide an organized and
efficient approach for tracking the progression of equipment/system test activities, collecting

EchoWater Project
data, reviewing and approving commissioning test results and deliverables, and ultimately
transferring select data to the Districts 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,
manufacturers 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 Commissioning Team
The commissioning team shall be made up of representatives from the Contractor, Design
Consultant, and the District (CM, O&M, and PMO). The Contractor shall assemble a
commissioning team under the direction of a Commissioning Coordinator, duly authorized to
commit the Contractors personnel and resources.
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 Contractors 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

EchoWater Project
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 Contractors
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
Contractors end-to-end tests verifying the PCCS end, respectively.
3.2.1.3 Design Consultant
The Design Consultant shall provide engineering support throughout pre-commissioning and
commissioning (i.e. reviewing the Contractors edits to the Commissioning Plan, submitting the
Draft and Final OMTG, maintaining and submitting the record CAD drawings and BIM
models, reviewing test results, conducting District staff training, process control, process
optimization, on-call support, etc.) and shall be available for on-site assistance when requested
by the District. The Design Consultant shall also review the proposed Commissioning
Coordinators qualifications and experience for compliance with the Specifications.
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
Manufacturers Installation Certification. The testing verifies that the installed hardware and
software conforms to the requirements of the Specifications and is ready for operation.
3.2.2.1 Pre-Commissioning Tests and Tasks
The completion of Pre-Commissioning shall be an indication that all equipment in the system
has been properly inspected, installed, lubricated, cleaned, checked for foreign materials,

EchoWater Project
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
Districts 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.
Table 3-2. Pre-Commissioning Tests, Tasks, and Responsibilities
Tests and Tasks Description Responsibility
1. Factory Demonstration Tests Factory tests customized specific to
the equipment being factory tested
and demonstrates compliance with
the Specifications.
Design Consultant to review test results.

District Engineering/PMO to witness,
review, and approve.
2. Delivery Acceptance Inspections Inspections to verify delivered
equipment conforms to approved
equipment submittals and are suitable
for installation.
District CM to inspect and document.
3. Equipment storage and
maintenance records up-to-date
Verify equipment storage,
maintenance, installation, and
servicing logs and records are
properly documented and kept up-to-
date as per manufacturers
instructions.
District CM to confirm.
4. Verification of installed assets
per design database
Equipment installation dates to be
documented in the BIM model; thus
the ability to track installation of all
assets.
5. Structural leakage tests Hydrostatic pressure tests for water
retaining structures.
District CM to witness.
Mechanical Equipment Tests
6. Mechanical pre-operational tests Pre-operational tests customized
specific to the equipment to verify the
equipments readiness to startup for
the first time by confirming the
installed equipment is in compliance
with the Specifications.

7. Piping systempressure and
leakage tests
Pressure and water leakage tests for
isolated portions of piping systems.

8. Piping systemcleaning and
flushing
Piping shall be cleaned followed the
pressure and leakage tests. Method of
cleaning is dependent on the type of
pipe and application as per the
Specifications.

9. Valve pre-operational tests Testing of valve operators to ensure
proper cycling.

10. HVAC pre-operational tests Verify the HVAC equipments
readiness to startup for the first time
by confirming the installed equipment
is compliance with the Specifications.


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Instrumentation Equipment Tests
11. Instrument calibration tests Prior to field testing, all
instrumentation will be calibrated to
accurately read and record operating
data.

12. Analog loop end-to-end testing
at PLCs and PCCs
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
fromthe computer systemand its I/O
equipment.

13. Analog loop end-to-end testing
at PCCS
District O&M to prepare PCCS control
strategies and facilitate the Contractors
end-to-end tests verifying the PCCS end.
14. Digital control and logic end-to-
end testing at PLCs and PCCs
Verify 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.

15. Digital control and logic end-to-
end testing at PCCS
District O&M to prepare PCCS control
strategies and facilitate the Contractors
end-to-end tests verifying the PCCS end.
16. Public address systempre-
operational tests
Demonstrates the operation of the
speaker and horn.

17. CCTV systempre-operational
tests
Demonstrates the operation of the
CCTV system.
18. Fire alarmsystempre-
operational tests
Inspection and acceptance testing
shall include a visual inspection of all
fire systemcomponents, and a
complete functional test to
demonstrate the operation of each
device following installation.
Tests shall demonstrate that the entire
fire alarmsystemfunctions as
intended. All circuits shall be tested:
automatic sprinkler (pre-action),
elevator recall, equipment shutdown
and alarmdevices.
19. Fiber optic cable pre-operational
tests
Each optical fiber shall be tested for
end-to-end OTDR trace and
attenuation for each installed span
after cable installation.

Electrical Equipment Tests
20. International Electrical Testing
Association (NETA) tests
Newly-installed power systems tests. District CM to witness.

21. Conductor tests Continuity and insulation resistance
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
operate and are correctly polarized,
that motors have correct rotation, and
that all three-phase receptacles have
correct phase sequence and polarity.


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23. Manufacturers Installation
Certification
After completion of equipment pre-
operational tests, the Contractor shall
arrange for the manufacturers
representatives to inspect and certify
installation and operation.

Factory Demonstration Tests
Equipment FDTs are customized specific to the equipment being factory tested and shall be
referenced and described in the individual equipment Specifications. If required for
particular equipment, the FDTs shall include the required performance for a successful test,
method of simulation, and test sheet. Documentation for the completion of a successful
FDT must be completed during Pre-Commissioning. FDTs shall also include timing
requirements for fixing a failed test, resuming/aborting, and rescheduling the FDT. District
Engineering/PMO shall have the option to witness the FDTs and will review and approve
the test results. The Design Consultant shall provide a review of the test results and submit
any comments to the District PMO representative.
Delivery Acceptance Inspections
Delivery acceptance inspections shall be performed on items delivered at the site or to any
authorized place of storage. District CM shall verify equipment and materials are of the
specified quantity, conforming to approved submittals, suitable for installation, and include
installation and maintenance recommendations from the manufacturer.
Equipment Storage and Maintenance
Once new equipment is shipped from the manufacturer, whether immediately installed or
stored in the warehouse, it is the Contractors responsibility to properly store, maintain, and
service the equipment until it has been accepted and turned over to the District
(commencement of Activation). This shall also include electrical gear and instrumentation,
which may have special storage requirements.
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 manufacturers 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.
Verification of Installed Assets
The District CM shall log the equipment installation dates for entry into the BIM models
and shall verify that all the equipment has been installed per the design database. The
Design Consultant shall maintain and update the CAD drawings and BIM models with the
installation dates and any discovered discrepancies.

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Structural Leakage Tests
Concrete tanks, channels, and other structures which have walls or slabs that are exposed or
common with areas occupied by equipment or personnel and subjected to hydrostatic
pressure shall be tested for water tightness. Testing consists of filling the tank with water to
the maximum operating water surface for at least 24 hours and documenting any loss of
water or noticeable leaks. District CM shall witness the structural leakage tests.
Mechanical Equipment Tests
Mechanical Pre-Operational Tests. The mechanical pre-operational tests are
customized specific to the equipment to verify the equipments readiness to startup for
the first time. These tests are used for large complex equipment or where factory
authorized technicians are required to inspect and perform the first startup. Prior to the
manufacturer installation certifications, the equipment items will be inspected by the
Contractor to verify that the installations are in compliance with the Specifications and
manufacturers recommendations. The Design Consultant shall prepare equipment pre-
operational test forms for inclusion in the Specifications (if not currently provided by
the District). In some cases, the test forms provided by the manufacturers in their
equipment submittals shall be used to document the tests. The manufacturers
representative shall also sign-off on the test forms during their visit for installation
certification. District CM shall witness the mechanical equipment pre-operational tests
as well as the manufacturers installation certification.
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.
Instrumentation Equipment Tests
Instrument Calibration Tests. Prior to field testing, all instrumentation shall be
calibrated to accurately read and record operating data. The Contractor shall check
instruments for correct operation and perform calibration tests for position, pressure,
level, flow, speed, and temperature as per the requirements of the Specifications. The

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Contractor shall follow a standard calibration procedure, complete standard calibration
forms, and place a calibration sticker on the calibrated instruments. Set points for each
instrument shall be recorded and tracked in the System Set Point List (located in the
FATs and RATs). District CM shall witness instrument calibration 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 Contractors 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 Contractors 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.

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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.
Electrical Equipment Tests
NETA Tests. The requirements of the International Electrical Testing Association
(NETA) include tests on newly-installed power systems and apparatuses before being
energized. These tests verify the equipment and installation comply with the
Specifications as well as with regulatory and safety requirements. District CM shall
witness all NETA tests.
Conductor Tests. Continuity and insulation resistance measurements shall be made on
conductors after wire pulling and prior to connecting equipment. Conductor to
conductor and conductor to ground insulation resistance shall be measured for all
circuits 120V and above except lighting and receptacle circuits. District CM shall
witness all conductor tests.
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.
3.2.2.2 Manufacturers Installation Certification
After the completion of equipment pre-operational tests, the Contractor shall arrange an
inspection of the installation by each equipment manufacturers qualified representative (per
the requirements of the Specifications). The manufacturer shall start and run the equipment in
the field for the first time to check for proper rotation, alignment, lubrication, abnormal
vibration, abnormal temperature, abnormal amperage draw, abnormal operation and provide
initial adjustments or calibrations as necessary for continuous operation. If necessary, the
manufacturer shall resolve assembly or installation problems attributable to, or associated with
their products and equipment. The time spent remedying defective work shall not reduce their
contractual site visit obligations intended for making inspections and normal adjustments. The
Contractor shall ensure the manufacturers representative sign the equipments pre-operational
and startup summary test form for each equipment item. The District CM shall witness the
inspections by the manufacturers.
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 manufacturers inspection.
The Commissioning Plan shall include steps taken to fill all tested process systems, except

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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 Districts
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.
3.2.2.3 Pre-Commissioning Deliverables
Pre-Commissioning deliverables and responsibilities are provided in Table 3-3.
Table 3-3. Pre-Commissioning Deliverables and Responsibilities
Deliverables Description Responsibility
1. Equipment submittals Vendor provided shop drawings,
material data, samples, and product
data.
District CM to receive and track
submittals fromContractor and
distribute to District PMO.

District PMO to distribute to Design
Consultant and respective District
Engineering/O&M stakeholders for
review.

District PMO to review, consolidate
comments, and submit to District CM or
Contractor.
2. Equipment performance
guarantees and warranty letters
A written document, provided by the
vendor or Contractor, which endorses
the quality of products or services,
along with an assurance to meet the
Specifications.
District CM to receive and track from
Contractor and distribute to District
PMO.

review.

Contractor.
3. RFIs and responses up-to-date The Contractor can request
information about the contract from
the client. The client or a
representative of the client responds
to the Contractors request.
PMO.

review.

Contractor.

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Deliverables Description Responsibility
4. Equipment O&M manuals Vendor provided equipment O&M
manuals prepared per the
requirements of the Specifications.
Contractor to submit prior to delivery
of equipment.
PMO.

review.

Contractor.
5. Contractors edits to
Commissioning Plan
Contractor to provide safety related
documentation, an updated
organization chart, edits to test plans
and procedures, updated training
information, and an updated schedule.
Contractor to submit for District
approval prior to 50% progress payment.

Design Consultant to review.

District O&M/PMO to review and
approve.
6. Draft Operator Manual &
Training Guide
Operator training guides. Design Consultant to submit to District
for review 150 days prior to start of
Clean Water Commissioning.

approve.
7. Final Operator Manual &
Training Guide
Reference tool for training during
Design Consultant to submit to District
for review and approval 60 days prior to
start of Clean Water Commissioning.

approve.
8. Record CAD drawings and BIM
models (includes MEL/MMI
design database)
Includes data fromthe approved
equipment submittals, comments
fromthe verification of the design
database, and Contractor red-lines.
Design Consultant to maintain and
submit Record CAD drawings and BIM
models.

District Engineering/O&M/PMO to
review and approve.
9. Equipment vendors and Design
Consultants training lesson
plans and course schedules
Vendor and Design Consultant lesson
plans and schedules for District staff
training.
Contractor and Design Consultant to
submit lesson plans to District prior to

approve.

Equipment Submittals
Equipment submittals include, but are not limited to, product data, shop drawings, test
procedures, test results, annotated PLC program listings, AutoCADgenerated 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

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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.
Equipment Performance Guarantees and Warranty Letters
Each equipment vendor and the Contractor shall provide performance guarantees and
warranty letters, which endorses the quality of products or services, along with the
assurance to meet the Specifications. The Contractor shall also provide a guarantee letter
stating the Work has been built in accordance with the contract requirements and agrees to
repair or replace defective workmanship or materials within a certain period of time. The
review process is consistent with the equipment submittals.
Requests for Information
The Contractor shall prepare a RFI when additional information, clarification or
interpretation of the Contract Documents is needed. RFIs may also be used for apparent
conflicts, inconsistencies, ambiguities, or omissions. The review process is consistent with
the equipment submittals.
Equipment O&M Manuals
The vendor provided equipment O&M manuals are instruction manuals for the safe
operation and maintenance of the equipment and shall conform to the requirements of the
Specifications. The manuals also include requirements for proper storage and maintenance
of the equipment that shall be submitted and approved prior to delivery. The Contractor
shall add the submission and approval of the equipment O&M manuals to the Critical Path
Method (CPM) schedule. The review process is consistent with the equipment submittals.
Contractors Edits to Commissioning Plan
After notice to proceed is provided to the Contractor, the Contractor shall review and
provide comments to the Design Consultants Commissioning Plan. The review process is
consistent with the equipment submittals.
Operator Manual & Training Guide
The OMTG serves as a training document to prepare and qualify operators (and other
crafts) to safely work and manage processes in designated areas of the plant. The Design
Consultant shall prepare and submit a Draft and Final OMTG to the District PMO
representative who shall distribute to the District O&M stakeholders for review. The
District PMO representative shall consolidate comments and submit to the Design
Consultant for editing or approval. The final OMTG will serve as the basis for the Design
Consultants portion of District staff training during Clean Water Commissioning.

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Record CAD Drawings and BIM Models
Record CAD drawings and BIM models shall show the actual as constructed conditions of
installed or modified systems, equipment and material at the time of field acceptance of the
related portions of work. The purpose of the record drawings is to provide accurate
information for the future modification, expansion, operation and maintenance of the plant.
From the Contractor red-lines, approved equipment submittals and District CM
documentation, the Design Consultant shall maintain and submit the record CAD drawings
and BIM models to the District PMO representative who shall distribute to the District
Engineering/O&M stakeholders for review. The District PMO representative shall
consolidate comments and submit to the Design Consultant for editing or approval.
Training Lesson Plans
Prior to District staff training, the Contractor and Design Consultant shall prepare and
submit formal written lesson plans and training materials to the District PMO
representative who shall distribute to the District O&M stakeholders for review. The
District PMO representative shall review, consolidate comments, and submit to the Design
Consultant for editing or approval. The Contractors portion of the training shall require the
equipment vendors to provide classroom and field training on the operation and
maintenance of the installed equipment. The Design Consultants training shall present the
content of the OMTG.
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.
3.2.3 Clean Water Commissioning
Clean Water Commissioning verifies the functionality of the equipment and systems by testing
the PLC control narratives, PCCS control strategies, and performing loop tuning to obtain the
desired process control response. This stage operates under clean water conditions and includes
activities such as the FATs and PATs. District staff training shall also be conducted and
completed during this stage of commissioning by the equipment vendors and Design
Consultant.
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.


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Table 3-4. Clean Water Commissioning Tests, Tasks, Deliverables, and Responsibilities
Tests/Tasks/Deliverables Description Responsibility
1. FATs Tests involving the operation of
hardware and software as an
integrated systemunder clean water
conditions.
Contractor to conduct tests, submit test
results, and system/component set point
lists.

District O&M/PMO to witness, review,
and approve test results.
2. Loop tuning Loop tuning shall demonstrate stable
operation of the loop under actual
operating conditions. This test shall
include adjustment of closed loop
tuning parameters.
District O&M to witness and approve.
3. PATs Validation of individual equipment
performance specifications under
clean water conditions.
Contractor to conduct tests and submit
test results.

4. Maintenance of equipment Ensure proper maintenance of
equipment per manufacturers
instructions.
Contractor to performand document
maintenance activities.

5. Certificate of Occupancy Approval fromthe Cosumnes Fire
District Fire Marshall to occupy
newly constructed
buildings/structures under their
jurisdiction/permit.
6. Completion of District staff
training
Equipment, system, and process
classroomand field training.
Equipment vendor and Design
Consultant provided training.

District O&M/PMO to attend training
sessions and track completion of training
sessions.

3.2.3.1 Functional Acceptance Tests
The FATs test all equipment, instruments, and software as integrated systems using clean water
under normal operating conditions and extreme design conditions (maximum and minimum).
The FAT tests ensure that the PLC, PCCS software, and operational control strategies are
working in conjunction with the hardware as intended. All operational control strategies shall
be tested unless relief is provided on an ad hoc basis. Each FAT shall operate for a continuous
period of 10 days or until successful completion of the test procedures, whichever is greater. If
the system under the test fails, the cause of the failure shall be identified and rectified by the
Contractor or Design Consultant and the entire FAT test shall be restarted from the beginning.
The Contractor shall document any failures and the corrective action required to restore the
system to proper operation in the Issues Log. Failures shall be defined in the Specifications.
Testing which involves shutting down and re-starting systems shall not be considered as
failures.

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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.
Table 3-5. Functional Acceptance Test Plan Outline
Heading Section Description
1. Overview a. Introduction Identify the systemto be tested.
b. Control strategies and modes of
operation
Identify the control strategies, modes of operation,
and protective interlocks to be tested.
c. Notifications Identify shutdowns and tie-ins.
2. Prerequisites a. Support systems Identify the equipment, systems, and media required
to conduct the FAT.
b. Related process systems
c. Test media
d. Measurement and test equipment
e. Temporary piping and equipment
configuration
f. Equipment and pipe labeling
g. Valve, Equipment, and
Instrumentation Lineup Tables
Identify equipment for tested systems and related
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.

The FAT sections are briefly described below.
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

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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.

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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.
3.2.3.2 Performance Acceptance Tests
The PATs validate the mechanical equipment performance requirements per the design intent
and Specifications. At a minimum, the PAT test plans shall include staffing for each test,
identifying roles and responsibilities, procedures clearly stating or listing test objectives
(acceptance criteria), and test descriptions. The PAT shall provide step-by-step descriptions of
the procedures proposed by the Design Consultant for the systematic testing of all equipment to
duplicate, as closely as possible, operating conditions described in the Contract Documents.
The Design Consultant shall prepare PAT procedures for individual equipment to include the
measurement of all operating parameters as specified in the appropriate equipment specification
section and identify the criteria (per the Specifications) that define a successful performance
test. The successful completion of a PAT occurs after the verification of the operating
parameters per the design intent and are not contingent on a continuous operating period. The
Specifications shall also include the required PAT test forms to document the test results.
Examples of pump PAT test forms are provided in Appendix A.
Pumps, Motor, and VFDs
Tests on pumps, motors, and VFDs shall be conducted to verify pump performance and
operation over the full range of flows. Equipment shall be operated to observe and record
operating and performance characteristics. Vibration, noise, temperature, amperage draw,
flow pressure, and other miscellaneous operating data shall be collected for each piece of
motorized equipment. For some equipment, this data shall be collected with the equipment
operating in up to four different conditions created by adjusting speed or a downstream
valve to create a backpressure. The data collected for a single equipment item is compared
with what is shown in its manufacturers literature. In addition to collecting the data
described above, settings for variable frequency drives, cooling water control, seal water
control and/or other auxiliaries shall be adjusted and readied for proper operation for the
various equipment items.
At a minimum, mechanical equipment requiring a PAT includes items such as pumps,
blowers/air handling units, valves greater than 48-inches, etc. These tests shall be
completed during the FATs and possibly repeated during the RATs, dependent on the
characteristics of the process water (i.e. mixed liquor, primary influent, etc.). During
Startup, the PATs shall include any required acceptance criteria for meeting process water
conditions. In lieu of mechanical, electrical, instrumentation, or power failures, conducting

EchoWater Project
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 Districts
Commissioning Integration Team (to be determined). Provided in Table 3-6 are the associated
Startup tests, tasks, deliverables, and responsibilities.


EchoWater Project
Table 3-6. Startup Tests, Tasks, Deliverables, and Responsibilities
Tests/Tasks/Deliverables Description Responsibility
1. RATs Tests demonstrating the continuous,
reliable operation of equipment and
control systems under process water
conditions.
Contractor to conduct tests, submit test
results, system/component set point lists,
issues logs, and data sheets.


District O&M/PMO to witness,
participate, review, and approve test
results.
2. Loop tuning Loop tuning shall demonstrate stable
operation of the loop under actual
operating conditions. This test shall
include adjustment of closed loop
tuning parameters.
District O&M/PMO to witness and
approve.
3. PATs Validation of equipment performance
specifications under process water
conditions.
Contractor to conduct tests and submit
test results.


4. Maintenance of equipment Ensure proper maintenance of
equipment per manufacturers
instructions.
Contractor to performand document
maintenance activities.

5. Site clean-up Construction site to be cleared of all
construction materials and cleaned.
Contractor to provide site clean-up.

District to confirmand accept.
6. District field inspection Provide final checkouts of equipment
and verify site cleanliness.
District CM/O&M/PMO to conduct.
7. Final Contractors punch list A final punch list of uncompleted
contract items.
District CM/O&M/PMO to generate for
Contractor to complete.
8. District Notice of Substantial Completion District CM/O&M to release after
completion of tasks.

3.2.4.1 Reliability Acceptance Tests
The RATs demonstrate the continuous operation of equipment and control systems per the
design intent. The RATs shall operate for a continuous period of 30 days. If the equipment or
system under test fails, the cause of the failure shall be identified and rectified by the
Contractor or Design Consultant and the entire RAT test shall be restarted from the beginning.
The Contractor shall document any failures and the corrective action required to restore the
system to proper operation in the Issues Log. Failures shall be defined in the Specifications.
Testing which involves shutting down and re-starting systems shall not be considered as
failures.
During the RAT, the Contractors 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

EchoWater Project
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 staffs 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.
Table 3-7. Reliability Acceptance Test Plan Outline
Heading Section Description
1. Overview a. Introduction Identify the systemto be tested.
b. Notifications Identify shutdowns and tie-ins.
2. Prerequisites a. Support systems Identify the systems required to conduct the RAT.
b. Related process systems
c. Valve, Equipment, and
Instrumentation Lineup Tables
Identify the equipment for the process, related
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 systemfailures
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.
c. Issues log

Identifies test failures and the corrective actions.

The RAT sections are briefly described below.
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.

EchoWater Project
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.
3.2.4.2 Performance Acceptance Tests
As specified in Clean Water Commissioning, equipment PATs may potentially be conducted
again during Startup to serve as a baseline condition for operation under process water
conditions (i.e. primary influent, mixed liquor, etc.) and to validate the equipment performance
specifications.
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.

EchoWater Project
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 Contractors 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.
Table 3-8. Activation Tasks, Deliverables, and Responsibilities
Tasks/Deliverables Description Responsibility
1. Punch list completion Contractor shall complete a punch list
of uncompleted contract items in
order to receive final payment.
Contractor to complete and the District
CM/O&M/PMO to verify.
2. District Notice of Field
Acceptance
Notice provided to Contractor,
confirming completion of contract
requirements.
Contractor to receive final payment.

District CM/O&M to release after the
completion of punch list items.
3. Commencement of warranty
period
District O&M assumes full
operational control of the plant and
initiates the start of the warranty
period.
District to operate and maintain plant
per manufacturer warranty
requirements.
4. Process optimization Adjust operating parameters to meet
process requirements.
Design Consultant to provide support
services for plant optimization.

District O&M/PMO to operate and
optimize plant processes.
5. Plant wide optimization Adjustment of plant wide processes to
meet process requirements.
District O&M/PMO to conduct.

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.

EchoWater Project
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 Contractors 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 Contractors expense. The intent of training
shall be to use the equipment O&M manuals as the principle basis for instruction.
3.3.2.2 Design Consultant
The Design Consultant required training shall cover the content of the OMTG: overview of the
equipment/systems/processes, controls, instrumentation, regulatory plant permit requirements,
plant workflow, troubleshooting, supporting documentation, and references. The training shall
include the current and future plans of operation. Prior to training, the Design Consultant shall
submit the Final OMTG for review and approval by the District O&M/PMO.
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.
3.4.2 Commissioning Activities
The Design Consultant shall prepare a preliminary schedule setting forth the sequence
contemplated for performing the test work for all equipment and systems to be tested as
described. The schedule shall be developed in conjunction with the construction operations
sequencing plan (prepared by the Design Consultant during Design) that will facilitate proper
testing of the equipment. The schedule shall show the contemplated start date, duration of the
test, and completion of each Pre-Commissioning, Clean Water Commissioning, Startup, and
Activation activity and deliverable (equipment O&M manuals, pre-operational tests,

EchoWater Project
manufacturers installation certifications, Contractors Commissioning Plan edits, Draft and
Final OMTG, Record CAD drawings and BIM models, FATs, PATs, RATs, District staff
training sessions, etc.).
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

APPENDIX A

TECHNICAL SPECIFICATIONS TESTS

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
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
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
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

40 61 13-D Miscellaneous Instrument Calibration Test
40 61 13-E Signal Trip Calibration Test
40 61 13-F Field Switch Calibration Test
40 61 13-G Pressure Gauge Test
40 61 13-H Transmitter Calibration Test
40 61 13-I Bubbler Tube Elevation Field Verification Test
40 61 13-J Analog Loop End-to-End Test
40 61 13-K Loop Tuning Test
40 61 13-L Digital Control and Logic End-to-End Test
40 63 43-A PLC Factory Acceptance Test Form
40 63 43-C PLC and Workstation System Availability Test
40 63 43-D PLC Field Acceptance Test Form
27 51 16 Public Address System Pre-Operational Test
28 23 00 CCTV Video System Pre-Operational Test
28 31 00 Fire Detection System Pre-Operational Test
7/22/2013 #####-1
SRWTP

CONTRACT # XXXX
SACRAMENTO REGIONAL WASTEWATER TREATMENT PLANT
ECHOWATER BNR PROJECT
PUMP PERFORMANCE TEST # ##### (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 XXXXXX.

Target Capacity,
GPM
Actual
Capacity,
GPM
Pressure
Loss,
PSI
Upstream
Head,
Ft
Downstream Head,
Ft
Motor Speed
RPM
Power Read
KW
Total
Motor Temperature
A B C D

Test Performed By:____________________________________________________________________________ Date:______________________
Witnessed By:________________________________________________________________________________ Date:______________________
Contractor
______________________________________________________________________________ Date:______________________
District
______________________________________________________________________________ Date:______________________
Manufacturer
Approved By:____________________________________________________________________________________________________________
District
Comments:______________________________________________________________________________________________________________
_______________________________________________________________________________________________________

7/22/2013 #####D2-1
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.

Record all test data on attached form.

Test Performed By:____________________________________________________________________________ Date:______________________
Witnessed By:________________________________________________________________________________ Date:______________________
Contractor
________________________________________________________________________________ Date:______________________
District
________________________________________________________________________________ Date:______________________
Manufacturer
Approved By:____________________________________________________________________________________________________________
District
Comments:______________________________________________________________________________________________________________

7/22/2013 #####D2-2
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

No.

Cap.
GPM

PSG/
in Hg

Feet
of
H
2
0

PSIG/
in Hg

Feet
of
H
2
0
Press
Diff
ft
H
2
0
(2-1)
El
Diff
gage
Cent.
Ft (3)
Frict.
Head
Ft
H
2
0
(4)
TDH
in ft
H
2
0
2-1
+3+4

H
2
0 HP
(7)

Watt
Mtr
KW

Volts

Amps

Pwr
Factr

Elec
HP
(8)

%
Eff
(7/8)
*100

Mtr

Erg

Midft

Pump Brgs
1
2
3
4
5
6
7
8
PUMP DATA:
Impeller Diameter:
Impeller Pattern:
PUMP MODEL:
PUMP SERIAL NUMBER:
PUMP SIZE:
CONDITIONAL NOTES:
TESTED BY:
TITLE:
DATE:
WITNESSED BY:
TITLE:
DATE:

APPENDIX B

APPENDIX B

FUNCTIONAL ACCEPTANCE TEST

EXAMPLES

APPENDIX B

EXAMPLES OF FUNCTIONAL ACCEPTANCE TEST GROUPS

Functional Acceptance Test Group Test No.
Primary Effluent Pump Station FAT-PEPS
Biological Nutrient Removal System FAT-BNR
Return Activated Sludge Pump Station FAT-RAS
Filter Influent Pump Station FAT-FIPS
Granular Media Filtration FAT-GMF
Sodium Hypochlorite System FAT-NaOCL

EchoWater Project
Solids Thickening and Processing Upgrades FAT - DAFTs-1
DAFTs

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.

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 Districts approval of the procedure
prior to the start of the FAT is required.
C. Alarms and interlocks are simulated in the field by activating the final element (sensor) or where
this is not possible, by simulating the test condition at field terminals as close as possible to the
final element. Calibration checks completed for the IAT will not be repeated.
1.3 COMPONENTS

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.

EchoWater Project
Part 5 Power Loss Simulation. This test will ensure back up power comes online
successfully and to ensure 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 the DAFT process areas:
1. Close the following valves:
a. DAFT feed sludge valves
b. Recycle pump suction and discharge valves
c. Verify all valves are closed on the TWAS, saturation system, and polymer piping
2. Open the following gates:
a. Open the underflow box effluent gate to allow underflow to flow to PEPS (applicable
for DAFTs A, B, and C) or to the WSSPS (applicable to DAFT D).
3. Open the following valves:
a. Back Pressure valve (on top of DAFT tank) unit fully open
4. Fill the DAFT tank with secondary effluent to prepare for the startup.
a. The water to be used for Part 1 of the FAT will be back fed from the secondary
effluent piping into the recycle piping as part of the permanent design as shown on
the Contract Drawings. This will require the normally closed secondary effluent valve
to be opened along with the recycle sump isolation valve. The recycle pump suction
valve and all other recycle suction valves shall be closed to route the secondary
effluent to the recycle sump being commissioned. The secondary effluent will fill the
recycle sumps and back feed into the submerged launder filling the DAFT tank.
b. The secondary effluent valve will be shut off once a DAFT liquid level elevation of
11.5 has been reached.
c. Temporary secondary effluent piping will connect to the influent WAS feed piping
upstream of the motorized feed valve and downstream of the manifold isolation valve
corresponding to the DAFT being commissioned. This will serve as the process fluid
for Part 2 of FAT testing and for the duration of the FAT. See Note 6 of Attachment 1
for temporary piping layout.
d. Note that it will be required to maintain a chlorine residual between 1 and 2 parts per
million in the process fluid used during the FAT period. Contractor shall be required
to add bleach or chlorine tablets as necessary to achieve the desired concentration.
EchoWater Project
General Notes:
1. Note: Unless otherwise noted use recommended set points specified in Attachment A of
Section 17300.
2. Note: Loop tags referenced below are typical for DAFT A equipment. This equipment is
typical for all DAFTs being commissioning unless otherwise noted.

EchoWater Project
Part 1: Saturation System
Test Procedure
# Test and Setup Required Results
Sign-off/
Comments
1 Test DAFT A Recycle Sump Isolation Valve (22IPV810A),
typical for all DAFTs, as follows:

Close valve
SCADA - CLOSED

Open valve
SCADA - OPENED

2 Fully open all valves on air panel except compressed air
line, rotameter bypass valves, pressure gage purge valves,
and line drain valves

3 Confirm back pressure valve is fully opened

4 Open isolation valve on pump suction piping and allow SE
to flow through the pump.

5 Bleed air from the pump and suction piping

6 Open pump discharge valve and jog pump to charge line

7 Open tank valves and close purge and drain valves for
Saturation Tank A Level Transmitter, (22ILIT842), typical
for all tanks.
SCADA Verify
Level follows Tank
Level for following
steps

8 Test DAFT A Air Control Panel, (22IFCP835A), typical for
all tanks as follows:

J og pump until saturation tank exceeds low level.
SCADA Low Level
goes OFF

Open compressed air valve on air panel. (Note saturation
tank operating pressures range from 65 to 80 psig.)
Confirm air
compressor is
producing a
minimum air
pressure of 100 psi
and that the outlet
PCV on the air panel
is initially set to at
least 70 psig.

J og pump until saturation tank exceeds air fill start level
setpoint.
SCADA Opens air
fill SOV

Set air fill rotameter at 3 cfm while filling
SCADA verify air
flow total matches
rotameter

J og pump until saturation tank exceeds high level.
SCADA High
Level goes ON

Drain saturation tank until level falls below tank purge start
SCADA Closes air
fill SOV, Opens tank

EchoWater Project
level setpoint. purge SOV
Set nitrogen tank purge rotameter at 3 cfm while venting
SCADA verify air
flow total matches
rotameter

9 Bring saturator to operating pressure with compressed air

10 Test Saturation Tank A Cross Connect Feed Valve
(22IFV833), typical for all tanks as follows:

Close valve
SCADA - CLOSED

Open valve
SCADA - OPENED

11 Open saturator tank discharge isolation valve

12 Test DAFT A/D Recycle Feed Valve, (22IBFV841H),
Typical for all DAFTs As follows:

Close valve
SCADA CLOSED,
Confirm valve
closed signal
ZSC841H received
at SCADA

Open valve
SCADA OPENED,
Confirm valve
closed signal
ZSC841H drops out
at SCADA

13 Test Standby Recycle Pump Suction Valve, (22IBFV831),
typical of two for each Standby Recycle Pump as follows:

At the FCP, place the MOV OCR selector in the CLOSE
position, valve closed.
At SCADA, verify
Closed status - ON

At the FCP, place the OCR selector in the OPEN position,
valve opens.
At SCADA, verify
Opened status - ON

At the FCP, place the OCR selector in the REMOTE
position, valve closes.
At SCADA, verify
Remote status - ON

Simulate MOV fail to open when called by SCADA.
At SCADA, verify
Fail - ON

Simulate MOV fail to close when called by SCADA.
At SCADA, verify
Fail - ON

Simulate valve trouble at MOV.
At SCADA, verify
Trouble - ON

Remove simulated alarms.
SCADA operates
MOV to Opened.

14 Test Standby Recycle Pump Discharge Valve,
(22IBFV833), typical of two for each Standby Recycle
Pumps as follows:

At SCADA, verify
Closed status - ON

valve opens.
At SCADA, verify
Opened status - ON

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At SCADA, verify
Remote status - ON

At SCADA, verify
Fail - ON

At SCADA, verify
Fail - ON

At SCADA, verify
Trouble - ON

SCADA operates
MOV to Opened.

15 Test Recycle Pump A, (22ITUB839), typical for all Recycle
Pumps as follows:

At MCC, place HOR selector switch in the Off Position,
LOS pushbutton in normal position
At SCADA, verify
Ready status- ON,
On Status - OFF,
Motor Overload Trip
- OFF, Motor High
Temperature - OFF,
Check Valve Fail to
Open - OFF

At MCC, place HOR selector in the Hand Position. Verify
that motor is running.
At SCADA, verify On
Status ON.

At Pump, place LOS pushbutton in Lockout position. At SCADA, verify On
Status OFF.

At Pump, place LOS pushbutton in Normal position. At SCADA, verify On
Status ON.

At MCC, verify Check Valve Fail to Open timer setting with
Wiring Schematic Drawing
At MCC, run the motor in Hand with the discharge check
valve closed longer than MCC timer setting.
Verify motor
stopped.
At SCADA, verify
Check Valve Fail to
Open - ON

Remove simulation of alarm condition. Verify that pump
does not restart

At MCC, place HOR selector in Off Position. Press Reset
Pushbutton.
At SCADA - verify
alarm is - OFF

At MCC, simulate Motor High Temperature
At MCC, run the motor in Hand longer than MCC timer
setting
Verify motor
stopped.
At SCADA - verify
Motor High
Temperature - ON

does not restart

Pushbutton.
At SCADA - verify
alarm is - OFF

At MCC, run the motor in Hand and simulate Overload Trip Verify motor
stopped.
At SCADA - verify
Overload Trip - ON

does not restart

At MCC, place HOR selector in Off Position. Press
Overload Reset Pushbutton.
At SCADA - verify
alarm is - OFF

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At MCC, place HOR selector in the Remote Position. At SCADA, verify
Remote - ON

At SCADA, request Manual Start Verify motor is
running. Verify
SCADA runtime
totalization

Simulate motor not running in Remote when called by
SCADA.
SCADA verify Fail -
ON

Simulate motor running in Remote when not called by
SCADA.
SCADA verify Fail -
ON

Temporarily close both pump suction MOVs Standby
Recycle only.
SCADA stops pump
Temporarily close both pump discharge MOVs Standby
Recycle only.
SCADA stops pump
16 Test DAFT A Saturation Tank Pressure Transmitter,
(22IPIT825) typical for all tanks when Recycle Pump is
pumping.
Verify pressure
reading matches
SCADA reading

17 Observe pressure in saturation tank and adjust conditions
to have a tank pressure of about 70 psi by gradually
opening the back pressure valve to decrease tank pressure
and gradually closing the back pressure valve to increase
tank pressure while continuing to gradually open the
saturator tank discharge isolation valve

18 Observe and verify that the saturation tank level is
maintained between selected setpoint levels while recycle
pump is pumping:
SCADA operates air
fill and tank purge
SOVs to cycle tank
level.

Temporarily stop recycle pump and close valves to hold
saturation tank level during air fill.
SCADA air fill fail
ON

Temporarily stop recycle pump and close valves to hold
saturation tank level during tank purge.
SCADA tank purge
fail ON

19 Test Saturation Tank Drain Cycle, typical for all tanks while
pumping as follows:

At SCADA, verify
Closed status - ON

valve opens.
At SCADA, verify
Opened status - ON

At SCADA, verify
Remote status - ON

At SCADA, verify
Fail - ON

At SCADA, verify
Fail - ON

At SCADA, verify
Trouble - ON

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Simulate MOV open for an extended period of time.
At SCADA, verify
Open Time Warning
- ON

SCADA operates
MOV to Opened.

20 Test DAFT A Recycle Flowmeter, (22IFIT843), typical for
all DAFTs as follows.when Recycle Pump is pumping.
Verify flow reading
and total matches
SCADA reading

21 Test Saturation Tank A/D Discharge Cross Connect Valve,
(22IBFV991I) as follows:

Close valve
SCADA - CLOSED

Open valve
SCADA - OPENED

22
At SCADA, request Recycle Pump Manual Stop

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Part 2: Feed Sludge System
Test Procedure
Sign-off/
Comments
1 Isolate line and test Scum from P2-90 Isolation Valve
(22IPV220G), typical for two as follows:

Open valve
SCADA - OPENED

Close valve
SCADA - CLOSED

2 Isolate line and test Scum/WS Crossover Isolation Valve
(22IPV220D) as follows:

Open valve
SCADA - OPENED

Close valve
SCADA - CLOSED

3 Isolate line and test WS from P2-90 Isolation Valve
(22IPV220C), typical for two as follows:

Open valve
SCADA - OPENED

Close valve
SCADA - CLOSED

4 Isolate line and test WAS from P2-90 Isolation Valve
(22IPV220W), typical for three as follows:

Open valve
SCADA - OPENED

Close valve
SCADA - CLOSED

5 Ensure manifold isolation valve is closed.
Test motorized DAFT A feed sludge valve (22IFV805),
typical for all DAFTs as follows:

At the FCP, place the MOV LOR selector in the LOCAL
position, close valve with CLOSE pushbutton.
At SCADA, verify %
Opened 0%

At the FCP, place the LOR selector in the position, open
valve with OPEN pushbutton.
At SCADA, verify %
Opened 100%

At the FCP, place the LOR selector in the REMOTE
position.
At SCADA, verify
Remote status - ON

Set SCADA to call valve to open to 50%.
At SCADA, verify %
Opened 50%

At SCADA, verify Fail
- ON

- ON

At SCADA, verify
Trouble - ON

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SCADA operates
MOV to Opened.

6 Route temporary secondary effluent piping and connect to
the influent WAS feed piping upstream of the motorized
feed valve and downstream of the manifold isolation valve
corresponding to the DAFT being commissioned. This will
serve as the process fluid for the duration of the FAT. See
Attachment 1 for temporary piping schematic.

7 Open DAFT A feed sludge valve.

8 Test the DAFT A waste sludge flowmeter (22IFIT801),
typical for all DAFTs as follows:

Place transmitter disconnect switch in OFF position.
SCADA, verify
Trouble - ON

Place transmitter disconnect switch in ON position.
SCADA, verify
Trouble - OFF

Simulate or provide flow through meter
Verify flow reading
and total matches
SCADA reading

9 Test the sludge total suspended solids analyzer
(22IAIT804) as follows:

Simulate analyzer trouble.
SCADA, verify
Trouble ON

Simulate analyzer value with known value % solids sample
Verify analyzer
reading matches
SCADA reading

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Part 3: DAFT Collection Equipment
Test Procedure
Sign-off/
Comments
1 Test DAFT A Gas Detection Panel (22IFCP806A), typical
for all DAFTs, as follows:

Place Panel disconnect switch in OFF position.
SCADA, verify
Trouble - ON

Place Panel disconnect switch in ON position.
SCADA, verify
Trouble - OFF

At FCP, simulate 10% LEL combustible gas.
At SCADA, verify
alarm - ON

At FCP, simulate low oxygen.
At SCADA, verify
alarm - ON

At FCP, simulate high H2S.
At SCADA, verify
alarm - ON

2 Verify the proper mechanical operation of the automated
underflow weir in the underflow box by lowering and raising
the gate through its full range of motion via local controls
on the actuator. Test gate (22IGAT814), typical for all
DAFTs, as follows:

At SCADA, verify %
Opened 0%

At SCADA, verify %
Opened 100%

position.
At SCADA, verify
Remote status - ON

At SCADA, verify %
Opened 50%

- ON

- ON

At SCADA, verify
Trouble - ON

SCADA operates
MOV to Opened.

3 Set DAFT liquid level setpoint at SCADA.
SCADA operates
weir to fill DAFT to
setpoint level

4 Verify operation of the DAFT A bubbler control panel
(22IFCP816), typical for all DAFTs, with the following
procedures:

Bubbler air supply turned off.
SCADA, verify Low
Air Pressure - ON

Open air supply valve, FCP instrument valves, close drain
valve, set pressure regulator, and set rotameter air flow.

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DAFT filling in process.
Verify bubbler level
reading matches
SCADA reading

Fill DAFT past High Level.
SCADA, verify High
Level - ON

At SCADA, set purge cycle frequency and duration time,
and initiate bubbler purge sequence.
SCADA, verify DAFT
level remains steady
during purge.
At bubbler, verify
purge sequence
closes level
transmitter valve, two
second delay, opens
purge solenoid, two
second delay, and
opens transmitter
valve

5 Test the DAFT A sweep (22IVFD810) controls, typical for
all DAFTs, as follows:

At VFD, place HOR selector switch in the Off Position, LOS
pushbutton in normal position
At SCADA, verify
Ready status- ON,
On Status - OFF,
Trouble - OFF, Motor
High Temperature -
OFF, High Torque
OFF, Over Torque -
OFF

At VFD, place HOR selector in the Hand Position. Verify
At SCADA, verify On
Status ON.

At Drive, place LOS pushbutton in Lockout position. At SCADA, verify On
Status OFF.

At Drive, place LOS pushbutton in Normal position. At SCADA, verify On
Status ON.

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
Pushbutton.
At SCADA - verify
alarm is - OFF

At VFD, simulate Motor High Temperature
At VFD, run the motor in Hand longer than VFD timer
setting
Verify motor stopped.
At SCADA - verify
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
Pushbutton.
At SCADA - verify
alarm is - OFF

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At VFD, simulate Trouble At SCADA - verify
Trouble - ON

At VFD, place HOR selector in the Remote Position. At SCADA, verify
Remote - ON

At SCADA, request Manual Start at Manual Speed of 0% Verify motor is
running minimum
rotational speed per
specification and that
sweep cannot be run
below minimum
speed. Verify
SCADA runtime
totalization. Verify
SCADA calculation of
RPH and MPR.

At SCADA, request Manual Start at Manual Speed of 100% Verify motor is
running, and speed is
100%. Verify SCADA
runtime totalization.
Verify SCADA
calculation of RPH
and MPR.

SCADA.
SCADA verify Fail -
ON

SCADA.
SCADA verify Fail -
ON

At SCADA set sweep duration and cycle frequency
setpoints. Set SCADA to Automatic.
Verify SCADA
operates sweep
start/stop per setpoint
times.

EchoWater Project
Part 4: Thickened Sludge System
Test Procedure
Sign-off/
Comments
1 Test the operation of DAFT A TWAS Telescoping Valve
(22ITSV815), typical for all DAFTs, through its full range of
motion via the motorized actuator. Follow additional testing
protocol as follows:
Verify liquid from
the DAFT tank is
discharged through
the valve when in
the low position.

At SCADA, verify %
Opened 0%

At SCADA, verify %
Opened 100%

position.
At SCADA, verify
Remote status - ON

At SCADA, verify %
Opened 50%

At SCADA, verify
Fail - ON

At SCADA, verify
Fail - ON

Simulate MOV open for an extended period of time.
At SCADA, verify
Open Time Warning
- ON

At SCADA, verify
Trouble - ON

SCADA operates
MOV to 50%.

At SCADA, set telescopic valve open start, cycle period,
duration, and position setpoints. Put valve in Automatic.
SCADA operates
MOV based on time,
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:

Bubbler air supply turned off.
SCADA, verify Low
Air Pressure - ON

Open air supply valve, FCP instrument valves, close drain
valve, set pressure regulator, and set rotameter air flow.

DAFT TWAS Sump filling in process.
Verify bubbler level
reading matches
SCADA reading

Fill DAFT TWAS Sump past High Level.
SCADA, verify High
Level - ON

At SCADA, set purge cycle frequency and duration time,
and initiate bubbler purge sequence.
SCADA, verify
DAFT level remains
steady during purge.
At bubbler, verify
purge sequence
closes level

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transmitter valve,
two second delay,
opens purge
solenoid, two
second delay, and
opens transmitter
valve
3 Open both DAFT TWAS pump suction and discharge
valves.

4 At SCADA, put telescoping valve in Automatic, MOV in
Remote to provide liquid into the sump for pump suction.

5 Test TWAS Pump A1 (22ITUB844) and TWAS Pump A2
(22ITUB847), typical for all DAFTs as follows.
TWAS pumps shall not be allowed to pump more than
25,000 gallons of plant or reclaimed water in a 24 hour
period to avoid diluting thickened sludge at the digesters.

At MCC, place HOR selector switch in the Off Position,
LOS pushbutton in normal position
At SCADA, verify
Ready status- ON,
On Status - OFF,
Motor Overload Trip
- OFF, Motor High
Temperature - OFF,
Check Valve Fail to
Open OFF, High
Discharge Pressure
- OFF

At MCC, place HOR selector in the Hand Position. Verify
At SCADA, verify On
Status ON.

At Pump, place LOS pushbutton in Lockout position. At SCADA, verify On
Status OFF.

At Pump, place LOS pushbutton in Normal position. At SCADA, verify On
Status ON.

At MCC, verify Check Valve Fail to Open timer setting with
At MCC, run the motor in Hand with the discharge check
Verify motor
stopped.
At SCADA, verify
Check Valve Fail to
Open - ON

does not restart

Pushbutton.
At SCADA - verify
alarm is - OFF

At MCC, run the motor in Hand longer than MCC timer
setting.
Verify motor
stopped.
At SCADA - verify
Motor High
Temperature - ON

does not restart

Pushbutton.
At SCADA - verify
alarm is - OFF

EchoWater Project

At MCC, run the motor in Hand and simulate Overload Trip Verify motor
stopped.
At SCADA - verify
Overload Trip - ON

does not restart

At SCADA - verify
alarm is - OFF

At MCC, verify High Discharge Pressure timer setting with
At MCC, run the motor in Hand and simulate high
discharge pressure longer than MCC timer setting.
Verify motor
stopped.
At SCADA, verify
High Discharge
Pressure - ON

does not restart

Pushbutton.
At SCADA - verify
alarm is - OFF

At MCC, place HOR selector in the Remote Position. At SCADA, verify
Remote - ON

At SCADA, request Manual Start Verify motor is
running. Verify
SCADA runtime
totalization

SCADA.
SCADA verify Fail -
ON

SCADA.
SCADA verify Fail -
ON

Test the second of two pumps per above steps.

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
vary DAFT Sump level above lead start setpoint.
SCADA starts lead
pump.

At SCADA, adjust telescoping valve in Manual to vary
DAFT Sump level above lag start setpoint.
SCADA starts lag
pump.

At SCADA, adjust telescoping valve in Manual to vary
DAFT Sump level below stop setpoint.
SCADA stops both
pumps.

At SCADA, put telescoping valve in Manual and adjust to
vary DAFT Sump level above lead start setpoint.
SCADA starts lead
pump.

Simulate pump failure for running pump. SCADA starts the
other pump.

Remove simulated pump failure.

Simulate pump failure for running pump. SCADA starts the
other pump.


At SCADA, put telescoping valve in Automatic.
6
After all eight DAFT TWAS pumps have been tested, put all
in Remote, and in Automatic at SCADA. Sequentially
adjust DAFT telescoping valves to raise sump level above
Verify that under no
conditions will
SCADA operate

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start setpoints. more then two of the
eight TWAS pumps
at a time, as
required for
hydraulic reasons.
7 Test the TWAS forcemain flowmeter (22IFIT434). Only
allow one TWAS pump to operate during testing so the flow
meter reads only the operating TWAS pump. Flowmeter
testing shall be conducted during the DAFT D FAT after all
other DAFTs have been commissioned.
Verify flow reading
and total matches
SCADA reading

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Part 5: Power Loss Simulation
Test Procedure
Sign-off/
Comments
Note: All non-DAFT system loads at the MCC shall be
locked out prior to power loss simulation testing.

1 Turn off feeder breaker for DAFT MCC at switchgear
SWGR-BC
Monitor to confirm
that status signals
from the DAFT
system are available
at the SCADA
powered by the UPS

Turn on feeder breaker for DAFT MCC at switchgear
SWGR-BC
Monitor to confirm
that status and
alarm signals are
reset and ready to
operate.

Polymer Storage and Feed Facilities See Polymer FAT
Note: Contractor shall test the polymer feed pumps and corresponding flow meters per Polymer FAT
requirements during the related DAFT FAT.

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INSERT
FIGURE
TEMPORARY SE PIPING FOR FAT

EchoWater Project
Solids Thickening and Processing Upgrades FAT - DIGESTERS-1
DIGESTERS

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 Districts 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 Districts 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.

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Part 3 Digester Mixing System. This test will check proper operation of the mixing
pumps, including all associated valves. A mixing efficiency test will be performed
using a lithium chloride slug injection followed by five hours of sampling.

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

EchoWater Project
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.

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d. Take a sample of the digester overflow prior to injection of lithium chloride. Note: All
sample bottles shall be marked with sample location, date and time (hour:minute).
e. Start the Digester I Grinder and Recirculation Pump
f. The CONTRACTOR with the ENGINEER present shall inject 51.3 lbs of lithium
chloride in a solution to the digester feed in a period of no more than three minutes.
Using a small Contractor-supplied pump, inject lithium chloride solution through the
2-inch sample valve PV919E. At the completion of the injection, start the clock for
subsequent sampling intervals.
g. After injection of lithium chloride, take samples at one-hour intervals for a period of
five hours at each of the following locations:
(1) the digester overflow
(2) recirculation pump sample port
(3) digester via the elevation well at elevations:
(a) 26 ft
(b) 16 ft
(c) 6 ft
h. The digester shall be fed continuously with plant water during the Digester Mixing
Performance Test and all equipment required for operation of the digester in active
mode will be operational except the Hot Water Pump.
i. Once sampling is complete, close plant water valve PV542A.
j. Remove temporary water meter and temporary piping to plant drain manhole.
k. Samples shall be analyzed for lithium chloride concentration by a certified laboratory
of the ENGINEERs choosing. The cost of sample analysis laboratory work shall be
borne by the OWNER.
l. The CONTRACTOR shall coordinate all arrangements for laboratory personnel,
sample bottles and other equipment. The CONTRACTOR shall arrange transport of
the samples to the laboratory. Following the Performance Testing and receipt of the
sampling results, the CONTRACTOR shall prepare a Digester Mixing System
Performance Test Report summarizing the digester mixing performance test results.
m. Passing Criteria: This Performance Test must demonstrate that the digester
achieves sufficient mixing such that the difference in lithium chloride concentration
between any sample taken in Hour Four or later of the Performance Test does not
deviate from the average of all samples taken in Hours Two through Five by more
than 10%.
F. Part 4: Booster Pump
1. The Booster Pump will not be tested during the Digester FAT.
G. Part 5: Transfer Pump
1. Ascertain that Digester J is ready for its FAT.
2. Set valve positions to prevent loss of water pumped to Digester J to other digesters or to
Dewatering pipes.
3. Set up the Digester I Transfer Pump to pump from Digester I to Digester J . Close any
valve that would allow any pumping of plant water from Digester I to other digesters
(besides J ) or to the Dewatering System.
4. Pump the content of Digester I to Digester J using the Digester I Transfer Pump.

EchoWater Project
a. Observe pump operation.
b. Record pump output at various manually-selected speeds, noting flow, discharge
pressure and both digesters levels at each data point. Verify and record maximum
pump output and minimum output as well as minimum of five intervening speeds.
c. Verify pump speed at SCADA responds to Operator selected speed in REMOTE
MANUAL.
d. In REMOTE AUTO Simulate pressure signal from the main dewatering feed pipe to
verify pump speed response to pressure.
e. Verify pump operation in Bottom Sludge Pumping Mode (pump start, volume
pumped, pump stop).
f. As Digester I level approaches elevation 12 ft, start a mixing pump and reduce
transfer pump speed so that the transfer flow is 600 gpm plus or minus. As level
drops, record digester level where the mixing pump begins to cavitate. Immediately
shut off mixing pump.
g. Record Digester I level where Digester I Transfer Pump begins to cavitate at plus or
minus 600 gpm. Immediately shut off transfer pump.
h. Secure Digester I Transfer Pump.
H. Secure Digester I and Prepare for Functional Acceptance Test for Digester J .

EchoWater Project
I. Part 2: Digester Heating and Recirculation System

Test Procedure

Test and Setup

Required Results

Sign-off/ Comments
1. Test Sludge Recirculation Discharge Pressure
Transmitter, typical for all Digesters
(25BPIT919), as follows:

Simulate or provide pressure to the transmitter Verify pressure reading
matches SCADA reading

Simulate or provide pressure to the transmitter
above low pressure setpoint
SCADA verify Low
Pressure - OFF

above high pressure setpoint
SCADA verify High
Pressure - ON

2. Test Sludge Recirculation Pump, typical for all
Digesters (25BPMP919), as follows:

At MCC, place HOR selector switch in the Off
Position, LOS pushbutton in normal position
At SCADA, verify Ready
status- ON, On Status -
OFF, Motor Overload Trip -
OFF, Motor High
Temperature - OFF, Check
Valve Fail to Open - OFF

At MCC, place HOR selector in the Hand Position.
Verify that motor is running.
At SCADA, verify On Status
ON.

At Pump, place LOS pushbutton in Lockout position At SCADA, verify On Status
OFF.

At Pump, place LOS pushbutton in Normal position At SCADA, verify On Status
ON.

At MCC, verify Check Valve Fail to Open timer
setting with Wiring Schematic Drawing
At MCC, run the motor in Hand and simulate low
At SCADA, verify Check
Valve Fail to Open - ON

Remove simulation of alarm condition. Verify that pump does not
restart

Reset Pushbutton.
At SCADA - verify alarm is -
OFF

At MCC, run the motor in Hand longer than MCC
timer setting
At SCADA - verify Motor
High Temperature - ON

restart

Reset Pushbutton.
OFF

At MCC, run the motor in Hand and simulate
Overload Trip
At SCADA - verify
Overload Trip - ON

restart

OFF

At MCC, place HOR selector in the Remote At SCADA, verify Remote -

EchoWater Project
Position. ON
At SCADA, request Manual Start Verify motor is running.
Verify SCADA runtime
totalization

Simulate motor not running in Remote when called
by SCADA.
SCADA verify Fail - ON
Simulate motor running in Remote when not called
by SCADA.
Start pump from SCADA. Simulate high discharge
pressure.
SCADA verify High
Discharge Pressure ON,
pump stops

Start pump from SCADA. Simulate low digester
level
SCADA verify Low Digester
Level ON, pump stops

Start pump from SCADA. Simulate grinder trouble. Verify SCADA stops pump
Start pump from SCADA. Simulate grinder high
temperature.
Verify SCADA stops pump
Start pump from SCADA. Simulate grinder overload
trip.
Start pump from SCADA. Simulate grinder current
trip.
3. Test Sludge Sludge Grinder, typical for all
Digesters (25BGDR569), as follows:

OFF, Motor High
Temperature - OFF,
Current Trip - OFF

Simulate Sludge Recirculation Pump run status to
Grinder MCC

At SCADA, verify On
Forward Status ON.

At Grinder, place LOS pushbutton in Lockout
position
OFF.

At Grinder, place LOS pushbutton in Normal
position
ON.

At MCC, verify Current Trip timer setting with Wiring
Schematic Drawing
At MCC, run the motor in Hand and simulate current
trip longer than MCC timer setting.
At SCADA, verify Current
Trip - ON

restart

Reset Pushbutton.
OFF

timer setting

restart

Reset Pushbutton.
OFF

Overload Trip
At SCADA - verify
Overload Trip - ON

EchoWater Project
restart

OFF

At MCC, place HOR selector in the Remote
Position.
At SCADA, verify Remote -
ON

totalization

by SCADA.
by SCADA.
Start grinder from SCADA. Remove simulated
Sludge Circulation Pump run.
Verify SCADA stops motor.
Start grinder from SCADA. Simulate grinder current
trip.
Verify SCADA reverse
cycles grinder to clear jam.

4. Test Hot Water Discharge Pressure Transmitter,
typical for all Digesters (25BPIT565), as follows:


SCADA verify Low
Pressure - OFF

SCADA verify High
Pressure - ON

5. Test Hot Water Pump, typical for all Digesters
(25BPMP565), as follows:

OFF, Motor High
Temperature - OFF, Low
Flow - OFF

ON.

OFF.

ON.

At MCC, verify Low Flow timer setting with Wiring
Schematic Drawing
At MCC, run the motor in Hand and simulate low
flow longer than MCC timer setting.
At SCADA, verify Low Flow
- ON

restart

Reset Pushbutton.
OFF

timer setting

restart

Reset Pushbutton.
OFF

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Overload Trip
At SCADA - verify
Overload Trip - ON

restart

OFF

Position.
ON

totalization

by SCADA.
by SCADA.
pressure.
SCADA verify High
pump stops

Start pump from SCADA. Simulate low discharge
pressure.
SCADA verify Low
pump stops

At SCADA, put pump in Remote Automatic. Start
pump.
Verify SCADA starts pump

6. Test Hot Water Supply Temperature Transmitter,
typical for all Digesters (25BTIT568), as follows:

Simulate or provide temperature to the transmitter Verify reading matches
SCADA reading

Simulate or provide temperature to the transmitter
above low temperature setpoint
SCADA verify Low
Temperature - OFF

Simulate or provide Temperature to the transmitter
above high temperature setpoint
SCADA verify High
Temperature - ON

7. Test Digester Heated Sludge Temperature
Transmitter, typical for all Digesters
(25BTIT573), as follows:

Simulate or provide temperature to the transmitter Verify reading matches
SCADA reading

Simulate or provide temperature to the transmitter
above low temperature setpoint
SCADA verify Low
Temperature - OFF

Simulate or provide Temperature to the transmitter
above high temperature setpoint
SCADA verify High
Temperature - ON

8. Test Hot Water Three-Way Valve, typical for all
Digesters (25BTV564), as follows:

Open air supply valve, gage valve, open electro-
pneumatic transducer isolation valves and close
bypass valve, and set pressure regulator for the
valve.

Start hot water pump.
At SCADA, set valve to Remote Manual. Request
valve to 0% - closed.
Verify valve position

Verify hot water circulation
pump is being recirculated
no hot water being added.

At SCADA, request valve to 100% - closed. Verify valve position

EchoWater Project
Verify hot water circulation
pump is not being
recirculated hot water is
being added.

Stop hot water pump. Verify SCADA closes valve
Start hot water pump.
At SCADA, set valve to Remote Automatic. Set Hot
Water Supply Temperature Setpoint.
Verify SCADA operates
valve to maintain setpoint

Start sludge circulation water pump. Verify SCADA closes valve
At SCADA, set valve to Remote Cascade. Set
Heated Sludge Supply Temperature Setpoint.
Verify SCADA operates
valve to maintain setpoint

9. Test Digester Bubbler Panel, typical for all
Digesters (25BFCP557), as follows:

Bubbler air supply turned off. SCADA, verify Low Air
Pressure ON, Low Level -
ON

Open air supply valve, FCP instrument valves, close
drain valve, set pressure regulator, and set
rotameter air flow.

Digester filling in process. Verify bubbler level reading
matches SCADA reading,
Low Low Level - ON

Fill digester past Active Low Level. SCADA, verify Low Level -
OFF

Fill digester past Holding Low Level. SCADA, verify Low Level -
OFF

Fill digester past Active High Level. SCADA, verify High Level -
ON

Fill digester past Holding High Level. SCADA, verify High Level -
ON

At SCADA, set purge cycle frequency and duration
time, and initiate bubbler purge sequence.
SCADA, verify level
remains steady during
purge.
At bubbler, verify purge
sequence closes level
transmitter valve, two
second delay, opens purge
solenoid, two second delay,
and opens transmitter valve

EchoWater Project
J . Part 3: Digester Mixing System

Test Procedure

Test and Setup

Required Results

Sign-off/ Comments
1. Test Digester Mixing Pump Suction Control
Valve, typical for all Digesters (25BFV540), as
follows:

Open air supply valve, gage valve, solenoid valve
isolation valve, and set pressure regulator for the
valve.

At the FCP, place the OCR selector in the CLOSE
At SCADA, verify Closed
status - ON

At the FCP, place the OCR selector in the OPEN
position, valve opens.
At SCADA, verify Opened
status ON

At SCADA, verify Remote
status - ON

Simulate valve fail to open when called by SCADA. At SCADA, verify Fail - ON
Simulate valve fail to close when called by SCADA. At SCADA, verify Fail - ON
Simulate valve air supply failure. Verify valve remains in last
position

2. Test Steam Clean Waste Control Valve, typical
for all Digesters (25BFV507), as follows:

valve.

status - ON

status ON

status - ON

position

3. Test Digester Mixing Pump 1 Discharge
Pressure Transmitter, typical for all Digesters
(25BPIT543), as follows:


SCADA verify Low
Pressure - OFF

SCADA verify High
Pressure - ON

4. Test Digester Mixing Pump 1, typical for all
Digesters (25BPMP543), as follows:

OFF, Motor High

EchoWater Project
Temperature - OFF
ON.

At Pump, place LOS pushbutton in Lockout position

OFF.

ON.

timer setting

restart

Reset Pushbutton.
OFF

Overload Trip
At SCADA - verify
Overload Trip - ON

restart

OFF

Position.
ON

totalization

by SCADA.
by SCADA.
pressure.
SCADA verify High
pump stops

Start pump from SCADA. Simulate low discharge
pressure.
SCADA verify Low
pump stops

Start pump from SCADA. Simulate low digester
level.
SCADA verify Low Level
ON, pump stops

Start pump from SCADA. Simulate suction valve
closed.
Verify pump stops
Pump 2 only open steam clean waste suction
valve only. Start pump from SCADA. Simulate
steam clean waste suction valve closed.
Verify pump stops
At SCADA, put pump in Remote Automatic, open
suction valve. Assign pump as lead.
Verify SCADA starts pump
At SCADA, put the other pump in Remote
Automatic, open suction valve. Assign pump as
standby.

Simulate pump failure for running pump. SCADA starts the other
pump.

Simulate pump failure for running pump. SCADA starts the other
pump.


EchoWater Project
K. Part 4: Booster Pump

Test Procedure

Test and Setup

Required Results

Sign-off/ Comments
1. Digester Bottom Sludge Flow Control Valve
(25BFV553), as follows:

valve.

status - ON

status ON

status - ON

position

2. Supernatant/OF Distribution Flow Control Valve
(25BFV556), as follows:

valve.

status - ON

status ON

status - ON

position

3. Supernatant & Bottom Sludge Flow Control
Valve (25BFV669), as follows:

valve.

status - ON

status ON

status - ON

position

EchoWater Project
5. Test Discharge Downcomer Level Transmitter
(25BLIT225), typical for four, as follows:

Simulate or provide pressure to the transmitter Verify level reading

above low level setpoint
SCADA verify Low Level -
OFF

above high level setpoint
SCADA verify High Level
- ON

Select all downcomer levels at SCADA. Simulate or
provide levels that are equal for all but one.
Simulate or provide level that is different for one.
SCADA verify High
Deviation Level - ON

Repeat simulation for one of the selected levels until
all are tested to generate the alarm.
SCADA verify High
Deviation Level - ON

6. Test Overflow Booster Pump Discharge
Pressure Transmitter (25BPIT582), as follows:


SCADA verify Low
Pressure - OFF

SCADA verify High
Pressure - ON

4. Test Overflow Booster Pump (25BPMP582), as
follows:

At VFD, place HOR selector switch in the Off
OFF, Trouble - OFF, Motor
High Temperature - OFF,
Check Valve Fail to Open -
OFF

At VFD, place HOR selector in the Hand Position.
ON.

OFF.

ON.

At VFD, run the motor in Hand longer than VFD
timer setting

restart

At VFD, place HOR selector in Off Position. Press
Reset Pushbutton.
OFF

At VFD, simulate Check valve Fail to Open.
timer setting
At SCADA - verify Check

restart

Reset Pushbutton.
OFF

At VFD, simulate Trouble At SCADA - verify Trouble
- ON

At VFD, place HOR selector in the Remote Position. At SCADA, verify Remote -
ON

At SCADA, request Manual Start at Manual Speed Verify motor is running, and

EchoWater Project
of 0% speed is the minimum
pumping speed per
specification. Verify
SCADA runtime totalization.
At SCADA, request Manual Speed of 100% Verify motor is running, and
speed is 100%. Verify

SCADA.

SCADA.
At SCADA, request Manual Start. Simulate high
discharge pressure
Verify SCADA stops pump.
At SCADA, request Manual Start. Simulate low
downcomer level for selected level.
At SCADA, request Manual Start. Simulate both
discharge valves closed.
Set SCADA for pump to Automatic. Verify SCADA starts the
pump and pumps to
maintain setpoint
downcomer level.

EchoWater Project
L. Part 5: Transfer Pump

Test Procedure

Test and Setup

Required Results

Sign-off/ Comments
1. Test Digester Transfer to Digester Control Valve
(25BFV549, 561, 563), typical for Digester I; J;
and K, as follows:

valve.

status - ON

status ON

status - ON

position

2. Test Digester I Transfer Pump Suction Control
Valve (25BFV545) as follows:

valve.

status - ON

status ON

status - ON

position

At the SCADA, place the valve in Automatic. Start
Digester I Transfer Pump using automatic batch
transfer.
Verify valve opens when
pump is called to start.

3. Test Digester Transfer Header Flow Control
Valve (25BFV548, 560), typical for Digester I and
J, as follows:

valve.

status - ON

status ON

At the FCP, place the OCR selector in the REMOTE At SCADA, verify Remote

EchoWater Project
position, valve closes. status - ON
position

4. Test Digester I Transfer Pump to SN/OF
Distribution Control Valve (25BFV550, 624),
typical for Digester I and J, as follows:

valve.

status - ON

status ON

status - ON

position

7. Test Digester Transfer Pump Flow Transmitter
(25BFIT547), typical for Digester I and J, as
follows:

Place transmitter disconnect switch in OFF
position.
SCADA, verify Trouble -
ON

Place transmitter disconnect switch in ON
position.
SCADA, verify Trouble -
OFF

Simulate or provide flow through meter Verify flow reading and total

5. Test Digester Transfer Pump (25BPMP580),
typical for Digester I and J, as follows:

At VFD, place HOR selector switch in the Off
OFF, Trouble - OFF, Motor
High Temperature - OFF,
Check Valve Fail to Open -
OFF

At VFD, place HOR selector in the Hand Position.
ON.

OFF.

ON.

timer setting

restart

Reset Pushbutton.
OFF

At VFD, simulate Check valve Fail to Open.
timer setting
At SCADA - verify Check

EchoWater Project
restart

Reset Pushbutton.
OFF

At VFD, simulate Trouble At SCADA - verify Trouble
- ON

At VFD, place HOR selector in the Remote Position. At SCADA, verify Remote -
ON

At SCADA, request Manual Start at Manual Speed
of 0%
Verify motor is running, and
speed is the minimum
pumping speed per
specification. Verify

At SCADA, request Manual Speed of 100% Verify motor is running, and
speed is 100%. Verify

SCADA.

SCADA.
At SCADA, request Manual Start. Simulate low
digester level.
At SCADA, request Manual Start. Simulate no
suction valve opened
At SCADA, request Manual Start. Simulate no
discharge valves opened.
At SCADA, request Manual Start for the fourth time
in one hour.
Verify SCADA will not allow
fifth pump start within one
hour.

Set SCADA for pump to Automatic, Digester in
Holding mode.
Verify SCADA starts the
pump and pumps to
maintain setpoint
dewatering feed pump
header pressure.

Set SCADA for pump to Automatic, Digester in
Active mode.
Verify SCADA starts the
pump and pumps to
maintain setpoint speed
until a certain batch flow
setpoint is reached.

EchoWater Project
M. Part 6 Power Loss Simulation

Test Procedure

Test and Setup

Required Results

Sign-off/ Comments
Note: All non-Digester system loads at the MCC
shall be locked out prior to power loss
simulation testing

1. Turn off feeder breaker for the Digester MCC-
SHC and MCC-SHD at switchgear SWGR-DCSL
Confirm that the status
signals from the
Digester area are
available at the SCADA
powered by the UPS

2. Turn on feeder breaker for the Digester MCC-
SHC and MCC-SHD at switchgear SWGR-DCSL
Confirm that the status
and alarms are reset
and ready to operate.

APPENDIX C

APPENDIX C
RELIABILITY ACCEPTANCE TEST

EXAMPLES

APPENDIX C

EXAMPLES OF RELIABILITY ACCEPTANCE TEST GROUPS

Reliability Acceptance Test Group Test No.
Primary Effluent Pump Station RAT-PEPS
Biological Nutrient Removal System RAT-BNR
Return Activated Sludge Pump Station RAT-RAS
Filter Influent Pump Station RAT-FIPS
Granular Media Filtration RAT-GMF
Sodium Hypochlorite System RAT-NaOCL

EchoWater Project
Solids Thickening and Processing Upgrades RAT - DAFTs-1
DAFTs

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.

1. Begin polymer batching 45 minutes prior to startup to allow proper aging
2. Startup the DAFT collector mechanism
3. Fully open back pressure control valve from top of DAFT tank
4. Startup air compressor system
5. Startup recycle pump

EchoWater Project
6. Adjust air panel valves, pump discharge valve, saturation tank inlet valve and back pressure
valve as needed to maintain optimum pressure of ~70 psi in the saturation tank and a well-
balanced water level variation (always maintain level within magnetic indicator range) in the
saturation tank
7. Begin feeding polymer to the polymer ring
Note: Contractor shall test the polymer feed pumps and flow meters per Polymer RAT
requirements during the corresponding DAFT RAT. If the corresponding DAFT completed its RAT
prior to polymer system commissioning the Contractor shall make arrangements to have the
DAFT in operation for the purpose of the polymer feed pump and flowmeter testing.
8. Begin influent sludge flow to DAFT by opening the corresponding DAFT feed valve
9. Startup the TWAS pumps

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

1.
Verify all required operational tests of mechanical and electrical systems have been
successfully performed.

2.
Ensure the following slide gates and valves are in the proper position for operation of
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

3.
Verify all valves are closed on the TWAS, saturation system, and polymer piping.
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

EchoWater Project
8.

Startup Saturation System
A. Fully open all valves on air panel except compressed air line
B. Confirm back pressure valve is fully open
C. Open isolation valve on pump suction piping and allow SE to flow through the
pump
D. Bleed air from the pump and suction piping
E. Open pump discharge valve and bump pump to charge line
F. Close discharge valve
G. Start up the air compressor
H. Open compressed air valve on air panel. Confirm air compressor is producing a
minimum air pressure of 100 psi and that the outlet PRV on the air panel is set to
at least 70 psig
I. Bring saturator to operating pressure with compressed air
J . Set nitrogen purge at _3_ cfm
K. Ensure water level in saturator is visible but at a low position
L. Start the pump and immediately open discharge valve (regulate if required for
BEP)
M. Recirculation seal water flow to recycle pump will automatically initiate at this
point.
N. Open saturator tank discharge isolation valve regulate to maintain water level at
mid-point
O. Observe pressure in saturation tank and adjust conditions to maintain a tank
pressure of about 70 psi by gradually opening the back pressure valve to
decrease tank pressure and gradually closing the back pressure valve to increase
tank pressure while continuing to gradually open the saturator tank discharge
isolation valve
P. Be sure to check pump operating pressure (make sure in range of BEP). Note
pump design flow and pressure is 1,344 gpm @ 178 feet. This will be an iterative
process of closing the back pressure valve and opening the saturator discharge
valve.
Q. Maintain the water level in the saturation tank within the low and high water levels
as indicated by the magnetic level indicator by purging the nitrogen and setting
the solenoid valve in Auto. It is important not to attempt to adjust the
operating pressure while the water level is being depressed or raised.
R. Observe and verify that the saturation tank level is maintained. The solenoid
valve should open and close at the specified set points and the water level should
rise after the solenoid valve opens and drop after the solenoid valve closes.

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

12. Open corresponding DAFT feed sludge valves

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.

EchoWater Project
7 Day Continuous Operating Test: After the startup activities have been successfully
completed, determine whether facilities and equipment are operating satisfactorily in a steady
state to allow start of 7-day test. Make adjustments as necessary before the start of the 7 day
testing 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 pumps 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.

EchoWater Project

5. The underflow weir gate shall control the liquid level in the DAFT tank. Liquid level in the
DAFT is determined by the DAFT tank bubbler panel. Ensure correct operation of the
pneumatically operated weir gate through its entire range of motion. The weir gate should then
be set at the elevation which results in accumulation of float at a depth of six inches above the
leading edge of the beach. This set point should be further adjusted based on optimum liquid
level as determined by sludge thickness testing.
6. During the day-shift of Days 3, 4, 5, and 6 the DAFT will be operated at design peak day flow
of 2.03 MGD. The Contractor shall make arrangements with Sanitation District O&M to
achieve peak flow conditions. This may require taking other DAFTs offline to compensate for
the increased flows. The entire sludge remover mechanism shall be performance tested by the
Contractor. At the peak design solids loading the collectors shall be operated to maintain a
constant float level. If the sludge builds up faster than it can be removed at maximum collector
speed, the test shall be considered a failure and the Contractor will be required to remedy the
problem. The DAFT unit manufacturer shall then provide advice on the proper adjustments to the
equipment as necessary to achieve the specified performance requirements and goals.
Adjustments shall include influent feedwell weir elevations, depth of submergence of float
collection skimmers, collector speed, number of float collectors in service, number of saturation
tanks in service, underflow weir gate level and back pressure control valve settings along with all
other adjustments referenced in this document and the contract documents. Contractor shall
demonstrate these adjustments along with all other adjustments and requirements as described
herein and in the contract documents.
Power Loss Simulation Testing:
Power loss simulation testing shall be conducted after the conclusion of the 7 day continuous
operating test but before the RAT calendar period expires.
Note: All non-DAFT system loads at the MCC shall be locked out prior to power loss
simulation testing.
1. Turn off feeder breaker for DAFT MCC at switchgear SWGR-BC. Monitor to confirm that
status signals from the DAFT system are available at the SCADA powered by the UPS.
2. Turn on feeder breaker for DAFT MCC at switchgear SWGR-BC. Monitor to confirm that
status and alarm signals are reset and ready to operate.

RAT Process Control Data Sheet Notes
Based on the anticipated average and peak WAS concentrations and flows, the following are
anticipated process conditions with one DAFT tank on-line:

WAS Concentration ~3,300 3,700 mg/L
WAS flow ~1,069 1,409 gpm
Pressurized flow ~953 1,430 gpm
Hydraulic loading ~0.9 1.2 gpm/ft2
Solids Loading ~18 27 lb/ft2d
Polymer Dosage ~7 - 14 lb/dry ton

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.

Solids Thickening and Processing Upgrades
EchoWater Project
SRCSD RAT - DAFTS-6

RAT ISSUES LOG

Issue
No.
Date
Received
Sent
By
Description Action By Finish
By
Evaluation and Action Comments Date
Complete

RATDAFTs
LOGSHEET
LabAnalysis
Required
Mon Tues Wed Thurs Fri Sat Sun YES/NO
A.SludgeFeedflowrateRecordedfromtheDAFT
influentsludgemeters.
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm NO
B.SludgeFeedTSSSamplefromtheWASfeed
piping. ____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L YES
C.SludgeFeedTSSSamplefromtheTSSmeter.
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L NO
D.TWAS%TSSampletakenfromsampleportnear
magmeter. ____
%
____
%
____
%
____
%
____
%
____
%
____
% YES
E.UnderflowTSSSamplefrompressurization
pump ____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L YES
F.SludgeBlanketThicknessMeasurewithsludge
judgeoradaptedRavenprobe(preferred) ____
in
____
in
____
in
____
in
____
in
____
in
____
in NO
G.Polymerdosageratelbsofpolymerperdryton
ofsolids ____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
Expectedaverage=7,maximum
=14
NO
Comments
Also,thefollowingparametersshouldbecalculatedfromthedatacollectedandrecordedonthelogsheets:
Samplingandmonitoringoftheprocesscontrolparameters(describedbelow)shouldtakeplaceevery34hoursfortheduration
oftheentiretestingperiodandrecordedonlogsheetsduringthetest.
RATLOGSHEETS
Day
Activity
EchoWater Project
RATDAFTs
LOGSHEET
LabAnalysis
Required
Comments
RATLOGSHEETS
Day
Activity
____
gpm/ft2
____
gpm/ft2
____
gpm/ft2
____
gpm/ft2
____
gpm/ft2
____
gpm/ft2
____
gpm/ft2
Basedontheanticipatedaverage
andpeakWASconcentrationsand
flows,thefollowingareanticipated
processconditionswithoneDAFT
tankonline:
Hydraulicloading~0.91.2
gpm/ft2 NO
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
Pressurizedflow~9531,430
gpm NO
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
CombinedWASConcentration~
3,300mg/L3,700mg/L
NO
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm WASFlow~1,0691,409gpm NO
____
lb/ft2d
____
lb/ft2d
____
lb/ft2d
____
lb/ft2d
____
lb/ft2d
____
lb/ft2d
____
lb/ft2d SolidsLoading~1827lb/ft2d NO
C.PolymerDosageCalculated
____
lb/TDS
____
lb/TDS
____
lb/TDS
____
lb/TDS
____
lb/TDS
____
lb/TDS
____
lb/TDS PolymerDosage~5lb/TDS NO
1.FeedSludgeSystem
A.RecordSludgeFlow
____
MGD
____
MGD
____
MGD
____
MGD
____
MGD
____
MGD
____
MGD NO
B.RecordFeedSludgeTSSmeterreading ____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L NO
StartingonDay1operatetheDAFTattheannualaveragecombinedsludgeflowof1.54MGD.Continueoperatingatthisflow
forDays2and7alongwiththenightshiftforDays3,4,5,and6.Flowadjustmentscanbeachievedbythrottlingthemotorized
DAFTfeedvalveviaCRISP.
A.HydraulicLoadingCalcuated
B.SolidsLoadingCalculated
EchoWater Project
RATDAFTs
LOGSHEET
LabAnalysis
Required
Comments
RATLOGSHEETS
Day
Activity
2.DAFTSweep
A.Recordthevariablespeeddrive ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm NO
B.RecordRunduration ____
min
____
min
____
min
____
min
____
min
____
min
____
min NO
C.RecordPolymerDosage
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt NO
D.RecordWaterLevelintheDAFT ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft NO
E.RecordThicknessofthefloatlayer ____
In
____
In
____
In
____
In
____
In
____
In
____
In NO
F.AnalyzeTWAS%TS ____
%
____
%
____
%
____
%
____
%
____
%
____
% YES
3.RecyclePump
A.RecordPumpFlow ____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm NO
B.RecordPressureinSaturationTank ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI NO
C.RecordAirflowintothesaturationsystem ____
cfm
____
cfm
____
cfm
____
cfm
____
cfm
____
cfm
____
cfm NO
4.TWASPumps
A.Selectaleadpump
B.SetlevelintheTWASsump
C.Verifythepumpstarts
D.RecordTWASPumpFlow ____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm NO
E.SwitchLeadPump
F.Verifythepumpstarts
G.RecordTWASPumpFlow ____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm NO
EchoWater Project
RATDAFTs
LOGSHEET
LabAnalysis
Required
Comments
RATLOGSHEETS
Day
Activity
5.Underflowweirgate
A.RecordliquidlevelintheDAFTTank ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft NO
B.Setelevationoftheweirgate ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft NO
C.RecordtheaccumulationofFloat ____
in
____
in
____
in
____
in
____
in
____
in
____
in NO
1.FeedSludgeSystem
A.RecordSludgeFlow
____
MGD
____
MGD
____
MGD
____
MGD
____
MGD
____
MGD
____
MGD NO
B.RecordFeedSludgeTSSmeterreading ____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L
____
mg/L NO
2.DAFTSweep
A.Recordthevariablespeeddrive ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm NO
B.RecordRunduration ____
min
____
min
____
min
____
min
____
min
____
min
____
min NO
C.RecordPolymerDosage
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt
____
lb/dt NO
D.RecordWaterLevelintheDAFT ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft NO
E.RecordThicknessofthefloatlayer ____
In
____
In
____
In
____
In
____
In
____
In
____
In NO
F.AnalyzeTWAS%TS ____
%
____
%
____
%
____
%
____
%
____
%
____
% YES
ThedayshiftofDays3,4,5,and6theDAFTwillbeoperatedatdesignpeakdayflowof2.03MGD.Repeattestconditions
EchoWater Project
RATDAFTs
LOGSHEET
LabAnalysis
Required
Comments
RATLOGSHEETS
Day
Activity
3.RecyclePump
A.RecordPumpFlow ____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm NO
B.RecordPressureinSaturationTank ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI NO
C.RecordAirflowintothesaturationsystem
____
cfm
____
cfm
____
cfm
____
cfm
____
cfm
____
cfm
____
cfm NO
4.TWASPumps
A.Selectaleadpump
B.SetlevelintheTWASsump
C.Verifythepumpstarts
D.RecordTWASPumpFlow ____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm NO
E.SwitchLeadPump
F.Verifythepumpstarts
G.RecordTWASPumpFlow ____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm NO
5.Underflowweirgate
A.RecordliquidlevelintheDAFTTank ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft NO
B.Setelevationoftheweirgate ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft NO
C.RecordtheaccumulationofFloat ____
in
____
in
____
in
____
in
____
in
____
in
____
in NO
EchoWater Project
EchoWater Project
Solids Thickening and Processing Upgrades RAT - DIGESTERS-1
DIGESTERS

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.

The Active Mode startup procedure outline will be as follows:

1. Start the hot water pump
2. Start the grinder
3. Start the recirculation pump
4. Start the mixing pump
5. Place the feed valves in Remote

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 digesters
EchoWater Project
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.

Startup Activity Active Mode

1.
Verify all required operational tests of mechanical and electrical systems have been
successfully performed.
A. District to purchase or check for availability of process control equipment prior to
startup (probes, meters, etc.)

The following activities shall be performed by District Staff

2.
Close the following valves, prior to filling the digester
A. Steam Cleaning Waste Valves (FV507)
B. Transfer Header Valve (FV545)
C. Transfer Pump Discharge Valve (PV580D)
D. Bottom Sludge Line (FV553)
E. Recirculation Discharge Valve (PV578)
F. Recirculation Bypass to J Valve (PV576)
G. Primary Sludge Feed Valve Digester I (FV 500)
H. TWAS Feed Valve (FV509)
I. Ferric Feed Valve (BV516C)
J . PV519 and PV819 (digester-to-Overflow Box high and low valves)

3.
Open the following valves, prior to filling the digester
A. Digester Gas Vent through Carbon Canister valves (top of digester dome) fully open
to permit air displaced by water to vent
B. Digester Overflow Box Valve PV520

4. Fill the Digester with sludge until sludge appears in the sludge overflow box.

The following activities shall be performed by the CONTRACTOR
5. Purge air from mixing pump discharge, open valves PV544D and PV543D
6. Purge air from recirculation pump discharge, open valves PV919B and PV917B
7. Purge air from overflow pump discharge, open valves PV555A
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
EchoWater Project
11.

Start the grinder
12. Start the recirculation pump
13. Adjust the temperature set point at TSC12A
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
17. Place the feed valves in Remote
18. Start the 20 day Active Mode RAT

EchoWater Project
20 Day Active Mode Test: After the startup, determine whether facilities and equipment are
operating satisfactorily to allow start of 20-day Active Mode test. Make adjustments as necessary.

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

2. Complete the 20-day Active Mode RAT
3. Power Loss Simulation Testing Power loss simulation testing shall be conducted at the
conclusion of the 20-day active mode test, but before the start of the holding mode. NOTE:
all non-Digester system loads at the MCC shall be locked out prior to power loss simulation
testing.
a. Turn off feeder breaker for the Digester MCC-SHC at switchgear SWGR-DCSL.
Confirm that the status signals from the Digester area are available at the
SCADA powered by the UPS.
b. Turn on feeder breaker for the Digester MCC-SHC at switchgear SWGR-DCSL.
Confirm that the status and alarms are reset and ready to operate.
4. Set the Digester I feed valves (PS and TWAS) to Close (either Local or Remote) and
coordinate with plant staff to change Digester I from Active to Holding Mode at a CRISP
station. District staff may require up to one full working day to make this change.

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.

1. Verify Digester J is empty or nearly empty.
2. Starting on Day 1 open and close valves to permit gravity transfer of the sludge from Digester
I to Digester J .
3. Allow the transfer to occur by gravity until the levels in the two digesters are nearly equal.
4. Open and close valves to permit the Digester I Transfer Pump to pump to Digester J .
5. Start the Digester I Transfer Pump at 50% speed.
6. Each day-shift hour, record the speed of the transfer pump, flow meter reading, level in each
of the two digesters, suction & discharge pressure gage readings. Vary the pump speed from
50% to 100% of full speed, recording pump speed, flow meter reading, level in each of the
two digesters, and pump suction & discharge pressure gage readings.
7. Do not leave the transfer pump running unattended. Stop the pump if day-shift ends before
transfer of Digester I content to J has been completed.
8. As Digester I level drops to 10-ft depth, run the transfer pump at 100% speed and monitor the
point where the pump begins to cavitate. At the point of cavitation, record pump vibration,
pump speed, pump suction & discharge pressure gages, and Digester I and J levels. Reduce
transfer pump speed to 90% or until cavitation ceases and record Digester I level and
Digester J level where cavitation occurred. Continue to monitor, adjust speed and record
EchoWater Project
speed and Digester I level at each adjustment where cavitation occurs. Do not adjust the
speed below the point where the flow meter reads 400 gpm.
9. If flow is at 400 gpm and cavitation occurs, record pump speed, pump suction and discharge
gages, stop the pump. Record the Digester I level and Digester J level. The CONTRACTOR
shall adjust the Low Level (Pump Stop) elevation to a level 0.25 feet above the point of
cavitation.
10. If the transfer pump does not cavitate at its low (400 gpm) speed, when Digester I level
reaches its Low Level (Pump Stop) elevation, allow the pump to be automatically stopped by
the control system.
11. Once the content of Digester I has been transferred to Digester J as much as possible using
the transfer pump, operate the Booster Pump to fill the remainder of Digester J until level
causes overflow at the Overflow Box. Reroute Booster Pump flow to Digester I (now in
Holding Mode) or stop the Booster Pump if Digester I will fill with supernatant by gravity flow.
12. Starting on the following weekday day-shift operate Digester I in the Holding mode and
Digester J in Active Mode.
a. Verify the PS and TWAS feed valves for Digester I are Closed.
b. Set valves to permit filling Digester I via gravity from the Supernatant Overflow
system. Record the time required until the level in Digester I stops rising.
c. Set valves to permit filling Digester I using the Booster Pump.
d. Start the Booster Pump in Remote / Auto.
e. Set valves to permit pumping of sludge from Digester I to Dewatering.
f. Record each hour the following for the Booster Pump:
i. Elevation at downcomers from Digesters D,G, L and P
ii. Speed of the pump
iii. Suction Pressure
iv. Discharge Pressure
g. Once level in Digester I reaches 20 feet, set valves to permit transfer pumping to
Dewatering.
h. Start the Digester I transfer pump in Remote / Auto
i. Verify pump speed responds automatically to pressure in the Dewatering Header
j. Record the following initially every 5 minutes, then hourly after the system
stabilizes:
i. Level in Digester I
ii. Pump Speed
iii. Dewatering Header pressure
iv. Pump Suction & Discharge Pressure
13. Vary the elevation setpoint in the Digester D,G,L and P from 10 ft. in 5-ft increments up to 30
ft. Record Booster pump speed every minute for five minutes after each change of setpoint
or until the system stabilizes.
14. Test all combinations of the pneumatically operated valves (set in Remote-Auto) in various
modes in accordance with tables in 17300-2.24 G. 4. f. For example, set the Digester I
Transfer Pump to discharge to Digester J with valves in Remote-Auto. Note that certain
modes for the pneumatically operated valves listed in the tables requires opening and closing
of manual valves as well.

EchoWater Project
Remainder of RAT Phase
If the 20-day test is successfully completed prior to the minimum 45 calendar day duration for the
Digester I RAT phase, transfer the sludge from Digester I to Digester J and conduct the Active
Mode RAT on Digester J . Concurrently, continue to feed Digester I and conduct the Holding
Mode RAT on Digester I. Following completion of the Active Mode RAT on Digester J , conduct
the Holding Mode RAT on Digester J .

Solids Thickening and Processing Upgrades
EchoWater Project
SRCSD RAT - DIGESTERS-7

STARTUP ISSUES LOG

Issue
No.
Date
Received
Sent
By
Description Action By Finish
By
Evaluation and Action Comments Date
Complete

RATDIGESTERSIANDJ
LOGSHEET
Mon Tues Wed Thurs Fri Sat Sun
1.ACTIVEMODE
RecordLevelinDigesterI ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
RecordSuctionPressureoftheRecirculation
Pump
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
RecordDischargePressureoftheRecirculation
Pump
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
RecordHeatExchangerTemperature
RecordTemperatureofSludgeIn(IntoHeat
Exchanger)
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
RecordTemperatureofSludgeOut(Outof
theHeatExchanger)
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
RecordTemperatureofHotWaterIn(Into
theHeatExchanger)
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
RecordTemperatureofHotWaterOut(Out
oftheHeatExchanger)
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
____
degF
RecordSuctionPressureofMixingPump ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
RecordDischargePressureofMixingPump ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
RecordPositionoftheThreeWayValve ____ ____ ____ ____ ____ ____ ____
2.TRANSFERMODE
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
RecordLevelinDigesterJ ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
3.RuntheTransferPumpat50%
RecordSpeedofTransferPump ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
Activity
Day
Comments
RATLOGSHEET
EchoWater Project
RATDIGESTERSIANDJ
LOGSHEET
Activity
Day
Comments
RATLOGSHEET
Recordtheflowmeter ____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
RecordSuctionPressureofTransferPump ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
RecordDischargePressureofTransferPump ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
3.RuntheTransferPumpat100%
RecordSpeedofTransferPumpat100% ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
4.RuntheTransferPumpat100%untilitstartsto
cavitate
RecordSpeedofTransferPumpatCavitation ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
EchoWater Project
RATDIGESTERSIANDJ
LOGSHEET
Activity
Day
Comments
RATLOGSHEET
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
5.Reducespeeduntilcavitationceases
RecordSpeedofTransferPump ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
____
gpm
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
6.StartBoosterPumptoemptytheremainderof
DigesterI
RecordSpeedofBoosterPump ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
7.HOLDINGMODE
RecordthefollowingfortheBoosterPump
RecordtheFollowingfortheBoosterPump
RecordtheSpeed ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
RecordtheSuctionPressure ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
EchoWater Project
RATDIGESTERSIANDJ
LOGSHEET
Activity
Day
Comments
RATLOGSHEET
RecordtheLevelinDigesterD ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
RecordtheLevelinDigesterG ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
RecordtheLevelinDigesterL ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
RecordtheLevelinDigesterP ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
RecordtheDischargePressure ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
StarttheTransferPump,sothatisrunsbasedon
thedewateringheaderpressure,Recordthe
following:
RecordtheSpeed ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
RecordtheSuctionPressure ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
RecordtheLevelinDigesterI ____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
____
ft
RecordtheDewateringHeaderPressure ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
RecordtheDischargePressure ____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
____
PSI
VarytheelevationsetpointinDigesterD,G,Land
P,Recordthefollowing:
RecordtheBoosterPumpSpeed ____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
____
rpm
EchoWater Project

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Commissioning Plan Preparation Guide

Sacramento Regional County Sanitation District

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