# 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:
Jog 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. Jog 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
Set nitrogen tank purge rotameter at 3 cfm while venting
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 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
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. 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 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, run the motor in Hand and simulate Overload Trip Verify motor
stopped.
At SCADA - verify Overload Trip - ON Remove simulation of alarm condition. Verify that pump
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 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. 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
Test Procedure
# Test and Setup Required Results 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% 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
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
Test Procedure
# Test and Setup Required Results 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 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% 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. 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
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 that motor is running.
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
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.
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
At SCADA set sweep duration and cycle frequency setpoints. Set SCADA to Automatic.
Verify SCADA operates sweep start/stop per setpoint times.
Test Procedure
# Test and Setup Required Results 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 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% 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 MOV open for an extended period of time. At SCADA, verify Open Time Warning - ON
Simulate valve trouble at MOV. At SCADA, verify Trouble - ON Remove simulated alarms. 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.
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 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 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 SCADA - verify Overload Trip - ON Remove simulation of alarm condition. Verify that pump
does not restart At MCC, place HOR selector in Off Position. Press
Overload Reset Pushbutton.
At SCADA - verify alarm is - OFF At MCC, verify High Discharge Pressure timer setting with
Wiring Schematic Drawing
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 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, 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
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.