Commissioning of Pump Systems at - Baywork · Commissioning of Pump Systems at East Bay Municipal...

Commissioning of

Pump Systems at

East Bay Municipal Utility District

March 20, 2019

Alex Borys, P.E., Cindy Wu, P.E., Besnik Miftari

Nathan Gronlund, P.E., Sonya Spala, P.E.

http://hrconnection/values

Agenda

2

Introduction to EBMUD

What is covered in the presentation, who are the presenters

Water Supply and Distribution

Who we are

Structure of Engineering Department

Background & Goals for Commissioning Program

Historic approach

New Commissioning Services Group (CSG)

Agenda, cont.

3

Commissioning Case Studies:

Chemical Feed Pump System

Vertical Turbine Pumps

Closeout Documentation

O&M manuals, SOPs, PM forms, training files, As-Builts, PLC

HMI and program files

Lessons Learned and Commissioning Goals

1.4 million Water Customers

685,000 Wastewater Customers

4

Water Supply & Service Area

Service Area

Major Infrastructure Assets

(water)

Raw Water System

• 7 reservoirs

• Aqueducts

Treatment System

• 3 inline WTPs

• 3 conventional WTPs

Distribution System

• 4,200 miles of pipeline

• 122 pressure zones

• 164 reservoirs

• 135 pumping plants

• 100 regulators/RCS

6

Who We Are

7

Who We Are

8

Design and construction of new or rehab

infrastructure projects

Develop pump specifications

and test procedures/forms

Inspect pump installation

and enforce design intent

9

Developed holistic field testing in early 2000s

Functional Test: all equipment and devices

Performance Test: selected equipment

Control Systems Functional Test: EBMUD staff only

Startup Test: All systems operated by EBMUD, contractor on

standby

Witness approach (functional & performance tests):

Contractor run, District witnessed to avoid any

disputed results

Design Engineers conducted the testing

Design Division

Provide technical expertise and leadership for all

commissioning related work to improve overall

safety, quality and reliability upon handover to the

client (O&M)

Enhance overall coordination and communication

between Design, O&M and Construction

Promote continuous design improvements by sharing

lessons learned

10

Dedicated Commissioning Services Group (CSG)

Created in 2017

Commissioning Services Group

11

CSG - How We Work

Design Construct Commission Operate

Planning Testing Start-up

Lessons

Learned

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12

Commissioning Flow and

Terms

Design Construction Operation

Assign Startup Team RolesDesign Eng.Startup Eng.

CM/CIClient (OMD)

Overview of Commissioning Services Group Roles & Responsibilities

Review 90% Documents

SpecsDWGs

Work RestrictionsProcess Strategy

Commissioning Plan

Conduct Commissioning Kickoff Meeting

Witness Equipment Functional Testing

- electrical- mechanical

- instrumentation

Review Commissioning

Submittals & RFIs

Attend Factory Test/Inspections

Write/Update Commissioning Plan& startup schedule

Perform process Training and

coordinate vendor training

Establish Startup Goals & Review P&IDs10%-50% stage

Support- PM document transfer

- As- built checks- O&M manuals

Conduct Walk-through with

O&M and Construction

Support Troubleshooting

as needed

Witness Performance

Testing

Support/Conduct ControlSystem

Functional Testing

RfIP

Coordinate (Operational) Startup Test

perf. by OMD staff

CoordinationWith Construction

and Client

RFS

Conduct Commissioning

coordination Mtg. w. Contractor*

Submit Daily Startup Reports

on EADOC

Prepare Commissioning

close-out Documentation

Prepare Commissioning

Memo to Construction

Submit commissioning

punch list to CM

Conduct Lessons Learned Mtg.

with Construction &

Design

NTP

Verify th

at test pre-req

uisites are m

et

Ap

pro

ve Test Rep

orts

13


Vertical Turbine System

Electrical

Mechanical

Commissioning Case Studies

14

Hydrogen Peroxide (HP)


15

What is Hydrogen Peroxide?

Disinfectant, bleaching

agent

Boiling point: 226°F,

freezing point: -33°F

Clear, soluble in water.

Pungent odor

Unstable and breaks down:

2 𝐻2𝑂2 → 2 𝐻2𝑂 + 𝑂2 + ℎ𝑒𝑎𝑡

Need degassing valves at

various points in piping

16

What is HP used for at EBMUD?

Remove excess ozone residual in drinking water

treated with ozone

𝐻2𝑂2 + 2 𝑂3 → 2 𝑂𝐻 ∙ + 𝑂2

Hydroxyl radicals (OH•) react with taste & odor

causing compounds (i.e.. MIB & Geosmin) in drinking

water

HP is dosed based on ozone dosage

Calculated mass ratio is 2.8:1 of 𝑂3 to 𝐻2𝑂2

In practice, 3.5:1 to 5:1 is used

17

What does the HP system

consist of?

High Temperature Can Indicate

Decomposition in Progress

Rapid Change in Tank Level Can

Indicate Leak

Storage Tank

Motorized Outlet Valve

Closes Upon Leak Detection Manual Drain Valve

18


consist of?

Manual

Operation

Only

135 gallons

6,000+ gallon

Containment

Volume above

Sump

Containment Sump & Sump Pump

19


consist of?

Submersible Sump Pump

BJM Pumps, TIGF 32-9NL

Pump Capacity: 46 GPM, 27 ft.

head

Vertical or horizontal

discharge

On/off mechanical switch for

level control

Pump material: Chemical

resistant NORYL resin

20

Standby Pump Can Serve

Any Ozone Contactor

Remaining 4 Metering Pumps Are

Dedicated to Specific Contactors

Metering Pumps


consist of?

21


consist of?

22


consist of?

Hydraulic Diaphragm Metering Pump Skid

Pulsafeeder, Pulsapro PP680

Pump Capacity: 4 GPH, 100 psi.

Type: Positive displacement

Protection against over-

pressurization

Points from pump skid to PLC:

Leak detection

High pressure

Flow control:

Manual: stroke length

Automatic: VFD

23


consist of?

Metering Pump Suction Piping Arrangement

Calibration Column

Metering Pump

& Motor

Leak Detection

Sensor

Pump Stroke

24


consist of?

Metering Pump Discharge Piping Arrangement

Pressure

Switch

Pressure

Relief Valve

Pressure

Gauge

Back

Pressure

Valve Pulsation

Dampener

25


consist of?

Piping Arrangement

& Instrumentation

Coriolis Flow Meter

Dilution Water

Flow Indicator

Dilution Water

Solenoid Valve

To

Co

nta

cto

r

Discharge

Degassing

Vent

26


consist of?

What Happens Inside a Contactor Basin

Ozone Diffusers

Hydrogen Peroxide Diffuser

Diluted

Hydrogen

Peroxide

27


consist of?

Control Panel & HMI

29

How does the HP system work?

Control modes

Dosage mode

Ratio mode

In both modes, flow meter provides feedback signal to

control metering pump speed

Key interlocks

Pump: various alarms

Tank: leak detection alarm

Pump operation interlocked with contactor status

Dilution water valve operation interlocked with metering

pump and contactor status.

30

How does the HP system work?

Metering Pump Control HMI Screen

31

HP System Startup Sequencing

HP System

Installed

MCC

Modifications

Complete &

Tested

Metering Pump

Startup,

Troubleshooting

Instrumentation

Calibration,

Troubleshooting,

Loop Testing

Establish

Communication

between Local

Control Panel &

DCS

Functional

Testing

(from Local

Control

Panel)

Functional

Testing

(remotely

from DCS)

Fill Tank with

Water

Drain

Water

from

Tank, Fill

with HP

Purge

Air,

Prime

System

with HP

Operate

System

with HP

With Water With Chemical

32

Instrumentation Startup Steps

Field calibration

Verify and document field

device setpoints

Point-to-point control loop

checks

Local and remote operation

of valves

Verify flow meter accuracy

33

Instrumentation Test Form

34

Pump Startup and Functional

Test Steps

Purge all air out of piping

Bump pump motor to verify correct rotation

Verify pump performance with calibration column

draw-down tests

Compare calibration column results to flow meter

readings

Test alarms & control interlocks

Pump alarms: fail to run, VFD fail, high pressure, leak

detection

Pump cannot operate when respective contactor is offline

Dilution water valve operation dependent on metering pump

& contactor status.

35

Pump Test Form

36

Pump Test Form

37

Issues Found & Resolution

Piping installation error: pumps pumping to incorrect contactor,

incorrectly dosing contactors

Contactor 4

Contactor 3

Contactor 2

Contactor 1

38


Re-programmed control system, rather than re-pipe system

Contactor 4

Contactor 3

Contactor 2

Contactor 1

PMP-501

PMP-401

PMP-201

PMP-101

39


P&ID Note:

Lack of air relief valves in suction piping - prevented proper

pump priming during startup

Missing degassing valve in suction piping - pressurized piping

when system is offline

40


Design clarification issued to add air relief valve and degas vents

41


Mal-functioned flow meters

Reading flow when there is no

flow

Incorrect/inaccurate dosage of

hydrogen peroxide

Flow meters are very sensitive to

movement/touch

Flow meter issue or installation

issue?

Replaced two flow meters,

performed field validation tests

42


Control system programming corrections

Erroneously latching alarms

Leak detection alarm

Incorrect mapping of points between contactors

Metering pump PID control loop tuning

43

Lessons Learned from HP

System Commissioning

Seek input from O&M staff during Design Phase

Drawings to clearly show all pressure relief and degassing valves

in piping

Closely inspect of piping installation against conformance

drawings

Ensure Contractor is flushing pipes prior to all testing (chemical

and water service), with substantial tracking and recording.

Request factory rep troubleshoot at first occurrence of flow

meter malfunction

Perform control system functional testing with PLC programmer

Coordination, coordination, coordination!

44

QUESTIONS

Chemical Feed System

Commissioning

45



Electrical

Mechanical


46

Design Review

Submittal Review

Factory Tests

Installation

Equipment

Integration

Field Startup and

Commissioning

Final Reports and

As-Built Drawings

Electrical System

Commissioning

47

Design Review

Design based on current codes, standards and

regulations

NFPA70 (NEC)

ANSI

IEEE

NEMA

Design for safety (NFPA 70E)

Circuit breaker remote racking mechanism

Remote open/close operation

Equipment status monitoring (hardwired and network

communication)

Design for equipment maintainability and

accessibility (NFPA 70B)

48

Submittal Review

Critical step to ensure that equipment to be provided:

Meets the design specification

Physical Size

Functionality

Compatibility with equipment from different vendors to

ensure successful overall system integration

Submittal reviews performed by design engineer and

commissioning engineer

Prevents costly changes and schedule delays during

Construction Phase

49

Factory Acceptance Test

Final step to ensure equipment to be provided meets

design specifications

Capture and implement design changes made

between Design Phase and Construction Phase

Prevents costly field changes and schedule delays

after equipment is delivered

50

Factory Acceptance Test

Portable generator section inaccessible prior to field modification

Before Modification After Modification

51

Equipment Installation

Visual inspection of equipment installation

Verify installation meets manufacturers

recommendation and current codes and regulations

Verify equipment clearance/accessibility for

maintenance

52


Incoming utility power switchgear for pumping plant

All power and control

wires terminated and

matching design

drawings

NETA Phase 1 testing

completed

Circuit breaker Trip Units

programmed based on

the Coordination Study

Arc Flash sticker

installed

53


Remote breaker operation panel

Mimic Bus corrected to match the actual installation

Incorrect Mimic Bus Correct Mimic Bus

54


Remote racking mechanism

• Verify the source for control power (120Vac) to

operate all the accessory devices

• Verify operation of all the accessories

• Verify clearances for front and back access

55


Circuit breaker removal lift truck and ramp

Test physical fit of

the accessory

Any special ramp

requirements

56


Motor Control Center for Pumping Plant

• Verify shipping splits between sections

• Main bus connections, Neutral bus, Ground bus

• Control wiring between sections

Neutral Bus not connected between sections

57

Field Startup and

Commissioning

Final visual inspection & walk-through with O&M and

construction team before energizing the equipment

Energization

Phase rotation checks with Utility and Generator power

Bump motors to check rotation

58

Field Startup and

Commissioning

PLC Control Panel for Pumping Plant

PLC control program uploaded

Point-to-point control loop checks

of field devices

Functional testing

Alarms

Interlocks

Control sequences

59

Field Startup and

Commissioning

PLC Control Panel HMI for Pumping Plant

Perform testing of all field devices from the end device to the HMI

Ideally initiate the actual condition for status, alarm, fault or analog signal at the

end device

Some failure modes need special setup to verify the operation of the system

60

Field Startup and

Commissioning

PLC Control Panel HMI for Pumping Plant

Controls Engineering group developed HMI screens to aid during commissioning

Verify device status directly on the HMI screen

61

Field Startup and

Commissioning

Motor Starter Vertical Turbine Pump Motor

62

Field Startup and

Commissioning

Motor Starter

Program Trip Units based on

Coordination Study

Install Arc Flash stickers

Program settings for Motor Soft starter

Motor FLA

Start/ Stop ramp times

Verify actual readings (amperage) with

the readings on the Softstarter display

63

Field Startup and

Commissioning

Vertical Turbine Pump

Motor winding heaters

Storage concerns during construction

and during commissioning

(condensation buildup)

Thermal switches interlocks to

motor starter

64

Field Startup and

Commissioning

Motor-Actuated Valve

Local/Remote Operation

Programming changes

Verification of limit switch

feedbacks

Adjustments/ programming

changes

65

Field Startup and

Commissioning

Pressure Transmitter

Initial checks of analog loops

from the device to HMI

using the vendor simulator

Final verification of analog

values with the system

running

Pressure Indicating Transmitter

Flow Indicating Transmitter

Temperature Indicating Transmitter

66

Documentation & Field Changes

Red-lined/ yellow marked

drawings based on

changes and testing during

commissioning

Coordinate with design

engineer on design

changes identified during

functional testing

Design, Commissioning

and Controls Engineers to

review final as-builts

67

Documentation & Field Changes

Completed test forms for individual devices

Completed test forms for complete system

integration

Final documentation to O&M groups

68

QUESTIONS

Vertical Turbine Pumps –

Electrical Commissioning

69



Electrical

Mechanical


70

Vertical Turbine Pump Commissioning

• Submittals

• Barrel Installation

• Factory Tests

• Field Tests


71

SUBMITTALS

Rotodynamic Design Analysis

• Natural Frequency: no critical or

resonant frequencies within ±20% of

operating speed

• Deflections – manufacturer’s

recommendations


72

FACTORY PERFORMANCE TEST

• Certified Pump Curve

• Noise Tests

• Vibration Test: Acceptance Criteria (ISO 10816-7)


73



74


HI 14.6-2016: Acceptance Criteria


75

FACTORY TOLERANCE


76

BARREL PLACEMENT

• True vertical: ±3/64” per foot of barrel

length

• Fill barrel with water prior to placing

concrete to reduce buoyancy

• Block and anchor in place


77

FIELD TOLERANCE


78

BARREL PLACEMENT


79

BARREL FLAT AND PARALLEL


80

BARREL FLAT AND PARALLEL


Barrel Machining.MOV

81

Alignment

using jacking

screws


82


Motor shaft run-out test


Pump Coupling

Couple motor and

pump shaft and

repeat run-out test

84

FIELD FUNCTIONAL TEST

Installation check and certification

• Calibration check of all related instruments

and Loop Checks to MCC and PLC

• Insulation resistance, rotation check

1 hour Run Test:

Recirc water or pump to distribution

monitor amps/volts and discharge water

temperature

Motor Test: full load amps check


85


Instrumentation Calibration

86


Loop Testing

87

FIELD FUNCTIONAL

TEST

• Installation check and

certification


Installation Check

88


Field Functional Test

89



90



91

FIELD PERFORMANCE TEST

• Pump Curve (within 3% of head and efficiency

at design point)

• Vibration Test: running and natural

frequencies (no natural frequencies within 15%

of operating speeds)

• Pump Deflections: ≤ manufacturer’s

requirements

• Sound Test (≤3 dBA above spec)


92


93

VIBRATION/DEFLECTION

• Transducers on XYZ axis at upper

and lower motor bearings

• Dial indicator at top of pump

head


94


NATURAL FREQUENCY TESTING

Background information/Shast Woods - Natural frequency test.MOV

95

QUESTIONS

Vertical Turbine Pumps –

Mechanical Commissioning

96


Commissioning system binders for O&M staff

Test results

Interconnect drawings

Control sequences

Field red-lines

97


Example signed test form

98


Example P&ID red-line

99


Example red-lined interconnect drawings

Lessons Learned

Roles and Responsibilities

100

Who is the lead: CSG? CM?

Contractor? O&M? Designer or

Consultant?

Decide who leads what efforts

Single-point authority for directing

each commissioning test program

Commissioning coordination memo

to Construction and client clearly

defines roles, responsibilities, and

limitations

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Lessons Learned

Design Phase

101

Design Contract Documents need to

include:

well spelled-out process control strategies

developed programming and HMI/SCADA

screens

Specify system integrator

Perform a commissioning review to

address:

Testing features built into the design – i.e.,

priming & flushing connections, pump

recirc loops, measurement points

How to bring a system on-line?

How do you get electric power? What

workarounds are necessary?

Lessons Learned

Construction Phase

102

District CSG to promote understanding of

commissioning process and workflow

Hold commissioning meetings with Construction team and

Contractor (kick off, later – weekly)

Explain Commissioning sequencing and importance of

Functional/Performance tests, Control System Functional Test,

Startup Test

Enforce inclusion of commissioning related tasks in Construction

Schedule and development of a separate, detailed commissioning

schedule

Share commissioning daily reports with O&M staff

Lessons Learned

Construction Phase

103

Enforce hold points

test submittals, labelling, as-builts, O&Ms, PMs etc. prior to

functional testing

Time assigned to testing should not be considered “float”

and should not be taken or negotiated to meet deadlines

District Training Coordinator:

Vendor Training: review training agenda and schedule just in

time to have meaningful field training next to classroom training

District Construction Team to:

Lead inspection of mechanical and electrical

equipment by EBMUD construction inspectors

during installation and prior to startup

104

Applying Lessons Learned

Commissioning & Start-up Coordinator Central Point of Contact

(one internal and one external personnel) for all commissioning-

related work.

CSG staff is preparing and sharing commissioning plans, test

procedures and test forms proactively, vs. reactively marking up

insufficient Contractor test submittals

Initiate and conduct courtesy walk-through inspections with

maintenance and operations staff prior to major startup

milestones (i.e. Energize MCC, pump system startup).

During Startup Phase, conduct short, informal morning

coordination meetings with Contractor foreman, resident

engineer, construction inspector and relevant O&M staff.


1. Issuing internal memo that outlines:

Major commissioning tasks

Spec sections related to tasks

Roles and Responsibilities

Internal groups responsible for tasks

Commissioning Flow Chart Guideline

2. Commissioning Kick Off Meeting

Share information with Contractor as guideline for scheduling

requested Contractor build in subtasks into 3-week look ahead

105


Commissioning Tasks & Responsibilities

106

Pumping Plant Commissioning

Flow Chart

107

108

Pumping Plant Commissioning

Flow Chart, detail

Applying Lessons Learned –

Contractor Comm. Schedule

109

Commissioning

Short/Long Term Goals

110

Train EBMUD construction inspectors in inspection of

electrical and controls equipment

Implement lessons learned from previous CSG

projects in master specs for new in-house and

Consultant-led Design projects

Incorporate commissioning plans and commissioning

sequencing flow charts into Design contract

documents

111

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