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
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 District’s 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
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.
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.