Orange County Sanitation District Solids Thickening And

Transcript

ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) TYPICAL SEQUENCE FOR "OPERATION PORTION" OF ELECTRICAL SYSTEM COMMISSIONING EID Equipment Tag NETA TESTS/Protective Devices/Arc Flash EID Equipment Tag EID Equipment Tag CERTIFICATION BY MANUFACTURER ELECTRICAL EQUIPMENT TESTS EID Equipment Tag CLEAN/FINAL CHECK BY CONTRACTOR EID Equipment Tag ENERGIZE Page 1 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) "OPERATION PORTION" OF ELECTRICAL SYSTEM COMMISSIONING NETA TESTS / PROTECTIVE DEVICES / ARC FLASH: As required by the Contract Documents, all "NETA tests" will be performed by an independent, third-party InterNational Electrical Testing Association (NETA) testing organization. "NETA tests" will be performed based on the InterNational Electrical Testing Association Standard for Acceptance Testing Specifications for Electrical Power Distribution Equipment and Systems. In accordance with Part 3.3D of Specification Section 16080, "NETA tests" consist of the following individual tests: • • • • • • • • • • • • • • • Low-Voltage Switchgear and Switchboard Assemblies Transformers, Dry-Type, Air-Cooled Fused and Non-Fused Switches, Air, Low-Voltage Circuit Breakers, Air, Insulated-Case/Molded-Case (≥100 amp frame) Circuit Breakers, Air, Low-Voltage Power Instrument Transformers (CTs, CPTs, and PTs) Metering Devices including power monitors Grounding Systems Rotating Machinery, ac Induction Motors, Generators (low-voltage ac motors ≥20 hp) Motor Control, Motor Starters, Low-Voltage Motor Control, Motor Control Centers, Low-Voltage Adjustable Speed Drives Surge Arrestors, Low-Voltage Emergency Systems, Uninterruptible Power Systems Emergency Systems, Transfer Switches (Section 7.1 of NETA) (Sections 7.2.1.1 or 7.2.1.2 of NETA) (Section 7.5.1.1 of NETA) (Section 7.6.1.1 of NETA) (Section 7.6.1.2 of NETA) (Section 7.10 of NETA) (Section 7.11 of NETA) (Section 7.13 of NETA) (Section 7.15.1 of NETA) (Section 7.16.1.1 of NETA) (Section 7.16.2.1 of NETA) (Section 7.17 of NETA) (Section 7.19.1 of NETA) (Section 7.22.2 of NETA) (Section 7.22.3 of NETA) In addition to performing the required "NETA tests", the third-party testing organization is required to set/program and test the adjustable/programmable protective devices in the field according to applicable NETA and manufacturers' requirements. The settings for these devices will be provided by OCSD. Lastly, in addition to performing the required "NETA tests" and setting/programming the protective devices, the Contractor (Berg Electric) will install the required arc flash labels in accordance with the NEC and Contract requirements. Said labels will be installed prior to energizing an electrical panel. CERTIFICATION BY MANUFACTURER: A qualified manufacturer's representative of the electrical equipment will perform an onsite inspection to determine whether or not their equipment has been properly installed and is ready to be energized. The determination of the manufacturer's representative will be based on that manufacturer's standard written procedures/criteria for certification. As a minimum, they will check operational functions, interlocks, and safety devices. If deemed acceptable, the manufacturer's representative will provide documentation certifying that their equipment is properly installed and ready to be energized. This documentation will be submitted to OCSD for approval prior to energizing. Page 2 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) Lastly, at the conclusion of the manufacturer's certification, Berg Electric will submit printouts for initial VFD, relays, and similar parameter settings to OCSD for review. These settings are required prior to commencing ORT-1. In addition, these settings may be changed during FAT and RAT. If changed, they will be documented in the final Vendor Equipment Manuals as required. ELECTRICAL EQUIPMENT TESTS: In accordance with Part 3.2D of Specification Section 16080, the following circuit and cable testing will be performed by Berg Electric (as applicable) prior to energizing an electrical panel: • • • • • • Continuity test of all conductors prior to termination Verification of landing and labels Performance of Insulation Resistance Tests Testing for short circuits and extraneous grounds Performance of functional tests of all circuits Simulation of all alarm conditions The testing described above will be performed for both "Power, Control and Lighting Circuits" (600 V and Below), and for "Instrumentation, Signal and Alarm Circuits" (Circuits 300 V and Below). Refer to the "Electrical Testing Procedure" for additional information (to be prepared by Berg Electric). CLEAN / FINAL CHECK BY CONTRACTOR: Berg Electric will ensure that all equipment is properly cleaned (inside and out) to the standards required by the manufacturer and OCSD inspector. As pieces of electrical equipment are energized, voltage and phasing will be verified. ENERGIZE: The electrical equipment will be energized in a systematic manner after coordinating and receiving approval from OCSD and the Construction Manager. Notice will be provided prior to actually energizing. An approved lock-out tag-out procedure will be implemented and maintained throughout the process of energizing equipment. The overall intent is to lock out electrical energy from equipment and circuits downstream of the portion being energized. After the system is energized and checked to the MCC and panels, the power will be locked out at the MCC breaker buckets. When electrical service is necessary, an authorized W.M Lyles representative will remove the appropriate lock(s) upon performing an inspection to confirm that it is safe to do so. Page 3 of 12 Page 4 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) "I/O PORTION" OF ELECTRICAL SYSTEM, PROCESS SYSTEM, AND SUPPORT SYSTEM COMMISSIONING ENERGIZATION OF ELECTRICAL GEAR: Refer to "Operation Portion" of Electrical System Commissioning herein. After the appropriate piece (or pieces) of electrical equipment is energized, proceed to the steps that follow. PRE-STARTUP INSTRUMENTATION & CONTROL: For a particular system (Electrical, Process, or Support System) and piece of equipment within that system, there are a certain amount of instrumentation and control pre-startup activities that will be performed prior to proceeding to ORT-1. As with the Electrical Equipment Tests performed prior to energizing a particular piece of electrical equipment, in accordance with Part 3.2D of Specification Section 16080, the following circuit and cable testing will be performed by Berg Electric (as applicable): • • • • • • Continuity test of all conductors prior to termination Verification of landing and labels Performance of Insulation Resistance Tests Testing for short circuits and extraneous grounds Performance of functional tests of all circuits Simulation of all alarm conditions The testing described above will be performed for both "Power, Control and Lighting Circuits" (600 V and Below), and for "Instrumentation, Signal and Alarm Circuits" (Circuits 300 V and Below). In addition, the following low voltage motor tests will be performed (in accordance with Part 3.2E of Specification Section 16080): For all motors (≥3 hp): • • • • • • Inspect nameplate, physical, mechanical, anchorage, and grounding Performance of Insulation Resistance Tests Check for proper torque of mechanical and electrical connections Check bearing oil/grease Check coupling alignment and shaft end play Rotate the motor For all motors (≥20 hp): • • • • Run uncoupled for durations specified in Contract Documents (i.e. 2 hours for motors above 100 hp and 30 minutes for motors 100 hp and below before the driven equipment is placed in service). Observe for vibration, noise, and excessive winding or bearing temperature rise. Check shaft rotation Check bearing lubrication and temperature Check for excessive vibration Page 5 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) With respect to instrumentation, the following pre-startup activities will occur (as applicable): • • • Inspect installation and connections Inspect and test all hardware point to point Calibrate instruments Refer to the "Electrical Testing Procedure" and "Instrumentation Testing Procedure" for additional information. "Electrical Testing Procedure" to be prepared by Berg Electric and "Instrumentation Testing Procedure" to be prepared by KBL. PRE-STARTUP MECHANICAL: For a particular system (Electrical, Process, or Support System) and piece of equipment within that system, there are a certain amount of mechanical pre-startup activities that can be performed prior to proceeding to ORT-1. These activities include, but are not limited to: inspecting the equipment for proper installation, manually operating installed valves, ensuring that all equipment tags and labels are installed, and completing all calibrations that can be completed prior to operating the equipment. FCP READY TO TEST INSPECTIONS (FCPRTTI): The FCPRTTI is performed after installing and energizing the field control panels (prior to ORT-1). Verification of proper construction, installation, and grounding (per requirements in Specification Sections 16080, 17405, and other related Division 16 and 17 Specifications) will be performed for the pertinent FCP. Berg Electric will conduct the inspections in accordance with the attached Field Control Panel Ready to Test Inspection Form. CONFIGURE PLC: This step refers to configuring the PLC that is associated with a specific piece of equipment. This refers to the Contractor's configuring of one of the following 4 PLCs: • • • • DAFTS PLC (22IFCP770) DAFTS Polymer PLC (22IFCP771) Digester C-K PLC (25BFCP723) Digester L-T PLC (25CFCP075) This work will be performed by KBL. At this time, it is not necessary for OCSD to have completed its programming on the SCADA side. OPERATIONAL READINESS TEST PART 1 (ORT-1): At the conclusion of the manufacturer's certification to energize pertinent electrical equipment, Berg Electric will submit printouts for initial VFD, RVSS, relays, and similar parameter settings to OCSD for review. These settings are required prior to commencing ORT-1. In addition, these settings may be changed during FAT and RAT. If changed, they will be documented in the final Vendor Equipment Manuals. ORT-1 is performed after installation and calibration of instruments is complete. The test purpose is to check and document that the complete control system, including I/O to/from the PLC register (but excluding the application software), is ready for operation. Also, the equipment will be tested in local/manual mode for operation and functionality. Page 6 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) Loop checks will be made as a part of ORT-1 and records will be kept for all testing. ORT-1 will test each control and signal circuit and demonstrate all hardwired logic. The operation of all switches, solenoids, transmitters, and indicators will be verified. Mechanical equipment will not be operated during ORT-1. Lastly, this testing will not be witnessed by OCSD. ORT-1 will be broken down by System Name and the specific primary piece of equipment (EID Equipment Tag) being tested. This primary equipment will generally be one of the ORTs listed on Pages 64 and 65 of Specification Section 01810 (e.g. Sump Pumps per ORT Form 001, UPSs per ORT Form 033, In-Line Grinders per ORT Form 213, etc.). In performing a particular ORT, multiple pieces of equipment will be tested. {After the loop checks for all primary equipment are complete, all equipment related to the P2-89 Project will have been tested}. For example, when performing ORT-1 for Sump Pump 2 Biofilter (EID 22IPMP632), other equipment tested will include: starter, switches, lights, moisture detector and switch, temperature sensor and switch, and various control signals at FCP, MCC, and PLC. A complete listing of equipment and ORT tests to be performed are covered by separate submittal. "GREEN-TAGGED": When ORT-1 is successfully completed (for a particular System Name and specific primary piece of equipment), the primary piece of equipment will be considered to be "Green-Tagged". This will not be a physical green-tag, but will indicate that this system/equipment (and all related equipment) is ready to proceed to ORT-2. "Green-Tag" status will be tracked in the Master Matrix. If equipment is found to be defective or non-operational during ORT-1, a physical red tag will be placed on the defective or nonfunctional equipment. If a physical red tag is placed, all pertinent portions of ORT-1 will be repeated until all equipment is determined to be fully functional (at which time the System, and primary piece of equipment, and all related equipment will be considered to be "Green-Tagged"). OPERATIONAL READINESS TEST PART 2 (ORT-2): After a particular primary piece of equipment is "Green-Tagged", ORT-2 will be scheduled with OCSD. ORT-2 is identical to ORT-1, except that it will now be witnessed by OCSD. There should be very little troubleshooting during ORT-2 since troubleshooting will have occurred prior to "Green-Tagging". As with ORT-1, records will be kept for all testing and mechanical equipment will not be operated. CRISP SOFTWARE LOADED BY OCSD: Prior to proceeding to ORT-3, OCSD will load its SAT database, CRISP graphics, and PLC program into the pertinent CRISP workstation(s). APPROVAL OF PRE-COMMISSIONING REPORT: OCSD must approve W.M. Lyles' Pre-Commissioning Report prior to proceeding to ORT-3. This report will be broken down into phases to accommodate the required sequence of work. The Pre-Commissioning Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Pre-commissioning Stage. OPERATIONAL READINESS TEST PART 3 (ORT-3): ORT-3 is essentially a repeat of ORT-2 except that HMI graphics will be used to start, stop, monitor, and control equipment automatically. ORT-3 will check the software logic and signals from the field to the CRISP operator interface stations. ORT-3 will be scheduled with and performed in conjunction with Page 7 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) OCSD. As with ORT-1 and ORT-2, records will be kept for all testing and mechanical equipment will not be operated. AVAILABLE FOR FAT (IF APPLICABLE): Upon the successful completion of ORT-1, ORT-2, and ORT-3, a particular System Name and specific primary piece of equipment (including all related equipment on the same loop) will be deemed to be "Available for FAT". FAT will be the first time that mechanical equipment is operated continuously. Not all equipment will be subject to FAT. In general, FAT is a combined effort between OCSD and W.M. Lyles. The combined software/hardware system is tested from this point forward. This test will be conducted for LOCAL control; REMOTE MANUAL control; REMOTE AUTO control; REMOTE CASCADE (if applicable) control. The purpose for the test is to insure that the PLC and Operator Graphics software configuration are working in conjunction with the hardware and plant as intended. This test is accomplished with the system online under normal operating conditions (to the fullest extent possible). Equipment will operate with Plant water. APPROVAL OF PHASE 1 COMMISSIONING REPORT: OCSD must approve W.M. Lyles' Phase 1 Commissioning Report prior to proceeding to RAT. This report will be broken down into phases to accommodate the required sequence of work. The Phase 1 Commissioning Report is a collection of all test reports, test data, certificates and commissioning forms that are produced during the Phase 1 Stage. READY FOR RAT: At this point, a particular System Name and specific primary piece of equipment (including all related equipment on the same loop) will be deemed to be "Ready for RAT". This will be with respect to the "I/O Portion" of a particular system (Electrical, Process, or Support System) and piece of equipment within that system. Page 8 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) TYPICAL SEQUENCE FOR "OPERATION PORTION" OF SUPPORT SYSTEM AND PROCESS SYSTEM COMMISSIONING ENERGIZATION OF ELECTRICAL GEAR System Name System Name CLEAN/FINAL CHECK BY CONTRACTOR HYDROSTATIC TESTS System Name CERTIFICATION BY MANUFACTURER System Name READY FOR PHASE 1 COMMISSIONING Page 9 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) "OPERATION PORTION" OF SUPPORT SYSTEM AND PROCESS SYSTEM COMMISSIONING ENERGIZATION OF ELECTRICAL GEAR: Refer to "Operation Portion" of Electrical System Commissioning herein. After the appropriate piece (or pieces) of electrical equipment is energized, proceed to the steps that follow. CLEAN / FINAL CHECK BY CONTRACTOR: W.M. Lyles will ensure that all equipment and piping is properly cleaned (inside and out) to the standards required by the manufacturers and OCSD inspector. W.M. Lyles will perform all pre-startup checks of the equipment and all connections (electrical, water, and air). The water and air systems will be checked by W.M. Lyles and eventually placed into operation. Appropriate subcontractors will perform the required checks and tests on their systems (e.g. HVAC by Anderson Air Conditioning). As an example, Anderson Air Conditioning will check the HVAC system, clean all equipment and ductwork, and install filters. The system will be air balanced after the equipment is started. HYDROSTATIC TESTS: W.M. Lyles will be performing hydrostatic testing on the various piping systems throughout the project. Hydrostatic testing of water and air piping systems associated with a particular support or process system must be successfully completed prior to determining that a particular support or process system is "Ready for Phase 1 Commissioning". CERTIFICATION BY MANUFACTURER: Qualified manufacturer representatives of all pertinent support and process system equipment will perform an onsite inspection to determine whether or not their equipment has been properly installed and is ready to be placed into operation. The determination of the manufacturer's representative will be based on that manufacturer's standard written procedures/criteria for certification. As a minimum, they will check operational functions, interlocks, and safety devices. If deemed acceptable, the manufacturer's representative will provide documentation certifying that their equipment is properly installed and ready to be placed into operation. This documentation will be submitted to OCSD for approval prior to placing into operation. READY FOR PHASE 1 COMMISSIONING: At this point, a particular Support or Process System Name (including all related equipment) will be deemed to be "Ready for Phase 1 Commissioning". This will be with respect to the "Operation Portion" of a particular Process or Support System, including all equipment within that system. Page 10 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) TYPICAL SEQUENCE FOR "PLC COMMUNICATION" COMMISSIONING EID Equipment Tag ENERGIZE EID Equipment Tag PLC COMMUNICATION READY TO TEST INSPECTION 1 EID Equipment Tag PLC COMMUNICATION READY TO TEST INSPECTION 2 EID Equipment Tag ORT-1, ORT-2, LOAD CRISP SOFTWARE EID Equipment Tag READY FOR ORT-3 Page 11 of 12 ORANGE COUNTY SANITATION DISTRICT SOLIDS THICKENING AND PROCESSING UPGRADE PROJECT NO. P2-89 OVERALL COMMISSIONING PROCESS SEQUENCE (NARRATIVE AND FLOW DIAGRAMS) (continued) "PLC COMMUNICATION" COMMISSIONING ENERGIZATION OF ELECTRICAL GEAR: Refer to "Operation Portion" of Electrical System Commissioning herein. After the appropriate piece (or pieces) of electrical equipment is energized, proceed to the steps that follow. PLC COMMUNICATION READY TO TEST INSPECTION 1 (PLCCRTTI-1): The PLCCRTTI-1 ensures that the PLC, Fiberoptic, and RIO FCPs (and related equipment) are installed and operating in accordance with the requirements specified in Specification Sections 16122, 17405, and other related Division 16 and 17 Specifications. The inspection will confirm the proper installation and operation of the PLC communication hardware. KBL will conduct the inspection in accordance with the attached PLC Communication Ready to Test Inspection Form. PLC COMMUNICATION READY TO TEST INSPECTION 2 (PLCCRTTI-2): PLCCRTTI-2 is identical to PLCCRTTI-1, except that it will now be witnessed by OCSD. There should be very little troubleshooting during PLCCRTTI-2 since troubleshooting will have occurred during PLCCRTTI-1. ORT-1, ORT-2, LOAD CRISP SOFTWARE: Refer to "I/O Portion" of Electrical System, Process System, and Support System Commissioning herein. READY FOR ORT-3: At this point, a particular communication panel (i.e. PLC, RIO, or FO Panel) is ready to proceed to ORT-3 (from a PLC Communication Commissioning standpoint). 1007-1P2-CP Item 4 (12/11/12) Page 12 of 12 FCPRTTI Test Date _________________ FIELD CONTROL PANEL READY TO TEST INSPECTION Project ID: ____________________ EID Tag No.:___________________ The Field Control Panel Ready to Test Inspection (FCPRTTI) is scheduled after the control panels are delivered, installed, grounded, and power is connected. The Inspection is performed by Berg Electric prior to ORT-1. Line 1 Description FCPRTTI ENCLOSURE INSPECTION AND TESTING Verify enclosures and instrumentation are labeled correctly. 2 Inspect enclosure for visible damage. Verify 316L stainless steel construction, if required. 3 Verify enclosure is cleaned out, no sharp edges or cuttings. 4 Verify door opens and closes smoothly. Verify windows and all gaskets are in place. Verify latches and locks operate smoothly. 5 Verify all devices and wireways are firmly attached. 6 Verify all communication cabling is neatly coiled and adequately supported. 7 Verify all wiring, both fiber optic and copper, are uniquely identified with District"s standard to/from tagging system. 8 Verify exhaust or circulation fans are operational, if applicable. 9 Verify fluorescent light(s) are operational. 10 Test every cable and wire termination by tugging on the conductor. 11 12 GROUNDING Verify that all electrical equipment is connected to the main grounding system. Measuring point to point, resistance shall not exceed 0.5 ohm. Test all communication cable grounds, resistance shall be less than 0.5 ohm. Verify no ground loops exist on the shields. Authorized Signature: Title or Position: Inspection Completion Date: 1007-1P2-FCP-RTT-InsFrm.xls (12/11/12) Page 1 of 1 Comments PLCCRTTI-1 Test Date _________________ PLC COMMUNICATION READY TO TEST INSPECTION PLCCRTTI-2 Test Date _________________ Project ID: ____________________ EID Tag No.:___________________ The PLC Communication Ready to Test Inspection (PLCCRTTI) is scheduled after energizing a panel that is directly related to PLC communication (i.e. PLC panels, RIO panels, or fiberoptic panels), and prior to ORT-1. The inspection verifies the proper installation of the communication system hardware and tests basic communication system operation. The inspection is conducted twice: PLCCRTTI-1 by the Contractor only and PLCCRTTI-2 in the presence of OCSD and/or its engineer. The descriptions listed below do not apply to all communication system panels; label items that do not apply to this panel as N/A. This is intended to be a universal form. Line Description 1 Check all F-connectors to ensure that only Modicon F-connectors were used. Check crimp at base of connector; crimp should not result in a pinched or crushed ferrule (if ferrule is deformed, the wrong crimping tool or jaw location was used). 2 Check that all F-connectors are gently wrench tightened. 3 Verify shielded cable is 75 ohm RG-6 (RG-11 for long runs). 4 Verify that taps are not installed near electrically noisy components, such as switching power supply, fluorescent lights, etc. 5 Ensure the last tap on the trunk has a Modicon precision trunk terminator installed on the out port of the tap. 6 Verify all RIO drop taps and splitter/combiners are installed on plastic isolators and not touching or connected to ground except by a ground wire at one location. 7 Verify that RIO cable is not sharply bent, maintaining at least the minimum bend radius at all times. Verify excess cable is coiled and tied to cable anchor. 8 Verify that each RIO cable is Modicon specified length of 8.5 feet or longer (with the exception of the 18" cable used for hot-standby CRP to inline self-terminating connections). 9 With the CPU running and the RIO online, run the RIO monitoring utility in Nxt for 10-15 minutes. Verify that no errors are recorded. 10 Verify initial Remote I/O Condition: Ready, Com Act, Active is lit. 11 Disconnect network A connection at splitter. Net A Error alarm light, no other change. Reconnect network A, Net A Error alarm light clears. 12 Disconnect network B connection at splitter. Net B Error alarm light, no other change. 13 Disconnect network A connection at splitter. No Net A Error or Net B Error alarm light. Ready, Com Act, Active not lighted. 14 Reconnect Network A connection at splitter. Net B Error light. Ready, Com Act and Active change to lighted. Reconnect Network B. 15 Select one each AI, AO, DI, DO (when available in the rack) from the rack. Manipulate the I/O point at the drop; confirm the PLC traffic cop responds. 16 Repeat above 6 steps for each remote I/O rack. 1 Check configuration of Ethernet support equipment, such as switches, transceivers, etc. 2 Verify all cabling is installed in correct location. Left NOE card is plugged into either the Top or Left N-Tron Ethernet Switch. Right NOE card is plugged into the Bottom or Right N-Tron Ethernet Switch. 1 Check Modbus Plus network taps, cable length between nodes must be at least 10 feet. 2 Middle taps must be pass-through, the two end taps must be terminated with a switch or jumper that connects the built-in internal terminating resistor across the two data lines. 3 Disconnect all of the Modbus Plus connectors (from the NOM cards, Bridge MUXes, etc.) and measure the resistance from Pin 2 to Pin 3, resistance should measure 60 ohms (two 120 ohm termination resistors in parallel. PLCCRTTI-1 REMOTE I/O TEST MODBUS ETHERNET NETWORK TEST MODBUS PLUS NETWORK TEST 1007-1P2-PLC-RTT-InsFrm.xls (12/11/12) Page 1 of 3 Comments PLCCRTTI-2 Comments PLCCRTTI-1 Test Date _________________ PLC COMMUNICATION READY TO TEST INSPECTION PLCCRTTI-2 Test Date _________________ Line Description 4 Verify cable connection and address settings for each VFD . All connections should come from a Modbus Plus Tap. 5 Initial Modbus+ Condition: Modbus + indicator blinks fast (6 times per second). 6 Disconnect Modbus+ at processor. Modbus+ indicator blinks three times, then pauses. 7 Reconnect Modbus+. Modbus+ indicator blinks fast. 8 Repeat above 3 steps for each Modbus+ module. 9 Connect a laptop to each local Modbus Plus highway prior to joining it to live network, and run Modbus Plus Stat. Monitor network activity to verify that all devices are shown with the correct address and no unexpected addresses are present. Verify that the token rotation time is low (<20 milliseconds). 1 Verify that all 115VAC jumpers are installed on all power supplies. 2 Verify rotary switches on the back of all CPUs cards are set to the correct Modbus Plus address. 3 Verify rotary switches for drop numbers on all CRA cards are set correctly. 4 Verify rotary switches on the back of all NOM cards are set to the correct Modbus Plus address. 5 Verify all clear plastic doors are installed with their insert cards. 6 Verify that all card models are per Contract Documents and per District's Traffic Cop. 7 Verify that no cards display any error codes with the whole system powered up, with District's Traffic Cop loaded. 8 Verify that the plastic covers are installed on the backplane card connector for all spare slots. 9 Verify that all keys are provided for the CPU and CHS cards. 1 Verify that 18" cable is installed on CRP card and that an inline terminating resistor is installed (resistor is directional, check orientation). 2 Verify that the correct Modicon splitter/combiner is installed for a hotstandby system. 3 Inspect fiber jumper between CHS modules. Verify jumper is not crushed, pinched, damaged or has any excessively sharp bends. Check that jumper is twisted from Rx/Tx of first CHS to Tx/Rx of second CHS. 4 Verify that that the top or left rack's CHS module is set for A and the bottom or right rack's CHS module is set for B. 5 Simulate bump-less transfer by cutting each PLC power supply one at a time. HALT processors and verify correct operation. 6 Set the A CHS module showing primary on it's display and the B CHS modules key switch set to the transfer position. Push and hold the B CHS modules transfer button for 2 seconds then release, to transfer the program from one PLC to the other. The Comm light on the B CHS module should blink rapidly several times and then stop, the module should then show Standby on its front display. Place the B CHS modules key switch in the Run position. Repeat the transfer in the reverse direction. 1 Disconnect primary rack Network A connection at Splitter A1. Remote I/O drop should indicate Net A error, Ready, and Comm Act. I/O modules should indicate active. The primary processor CHS state should indicate Primary. Reconnect to Splitter A1, Net A error clears. 2 Disconnect primary rack Network B connection at Splitter A1. Remote I/O drop should indicate Net B error, Ready, and Comm Act. I/O modules should indicate active. The primary processor CHS state should indicate Primary. EID Tag No.:___________________ PLCCRTTI-1 PLC CARDS HOT-STANDBY SYSTEMS TEST PRIMARY NETWORK 1007-1P2-PLC-RTT-InsFrm.xls (12/11/12) Project ID: ____________________ Page 2 of 3 Comments PLCCRTTI-2 Comments PLCCRTTI-1 Test Date _________________ PLC COMMUNICATION READY TO TEST INSPECTION PLCCRTTI-2 Test Date _________________ Line Description 3 Disconnect primary rack Network A connection at Splitter A1. Primary processor should lose Primary indication on CHS module; secondary processor should become Primry controller. Secondary CHS should show Primary. Remote I/O drop should not have a Net A error or Net B error. I/O modules should indicate Active. 4 Reconnect primary rack Network A. No change to status lights. 5 Disconnect secondary rack Network A connection at Splitter A1. Remote I/O drop should indicate Net A error, Ready, and Comm Act. I/O modules should indicate active. The secondary processor CHS state should indicate secondary. Reconnect to Splitter A1, Net A error clears. 6 Disconnect secondary rack network B connection at Splitter A1. Remote I/O drop should indicate Net B error, Ready, and Comm Act. I/O modules should indicate active. The secondary processor CHS state should indicate secondary. 7 Disconnect secondary rack network A connection at Splitter A1. Secondary processor should lose secondary indication on CHS module; secondary processor should become Primry controller. Secondary CHS should show secondary. Remote I/O drop should not have a Net A error or Net B error. I/O modules should indicate Active. 8 Reconnect secondary rack network A. No change to status lights. EID Tag No.:___________________ PLCCRTTI-1 Authorized Signature: Title or Position: Inspection Completion Date: 1007-1P2-PLC-RTT-InsFrm.xls (12/11/12) Project ID: ____________________ Page 3 of 3 Comments PLCCRTTI-2 Comments