MONICA_(Control_Panel___Appendix_C_-_Spec_16750_Pump_Control_Panel_Testing).docx

SPECIFICATIONS

SECTION 16750

PUMPS CONTROL PANEL TESTING

GENERAL

DESCRIPTION

A. Section Includes: Requirements for installing and testing WSSC’s Pump Control Panel (PCP), and/or modifications to existing Pump Control Panel as indicated on drawings.

REFERENCES

Underwriters Laboratory UL508A – Safety Standards for Industrial Control Panels

National Electric Code Section 409 – Industrial Control Panels

NEMA 250-2008 – Enclosures for Electrical Equipment

QUALITY ASSURANCE

Work: Follow approved trade practices, manufacturer’s recommendations, and applicable federal, local and state codes.

Conduit connections/penetration to cabinet: Located at the side of the cabinet as close to the bottom as possible; or the bottom of the cabinet as close to the side as possible.

Connections shall not interfere with installation of the backplane or operation of the door.

Connections to the top or back of the cabinet will not be permitted without prior approval from the Commission.

Continuously protect and cover equipment from metal shards, dust, debris, and moisture.

Submit penetration detail or mark indelibly on the panel the penetration locations for field acceptance.

SUBMITTALS

Submit following Section 01330.

Denote on As-built Drawings for Pump Control Panel.

Denote on Final As-built Drawings.

Wiring between Pump Control Panel interface terminal strip, including terminal and wire numbers for wiring to field device, Motor Starters and DPCS panels.

Power connections to Pump Control Panel and other devices.

Show all conduit and corresponding destination.

Coordinate with point-to-point wiring documentation showing at a minimum:

Wiring between Pump Control Panel interface terminal strip, including terminal and wire numbers for all wiring to the field device and SCADA RTU enclosures.

Power connections to Pump Control Panel and other devices.

Final as-built drawings.

Submit following Section 01450.

Developed system test check for Engineers approval.

Include check box for Contractor and Engineer initials for each test as outlined under PART 3 Execution.

Final test check-sheets after successful completion of PCP field test.

STORAGE, AND HANDLING

Acceptance at Site: Inspect all materials and equipment against approved shop drawings at time of delivery. Immediately notify the Engineer if any damage.

Storage and Protection: Label all equipment and materials after they have been inspected. Storage all equipment and materials in dry, covered, ventilated location. Protect from harm in accordance with manufacturer’s recommendations.

Cover and protect exposed surfaces during installation and until Substantial Completion.

PRODUCTS

GENERAL

A. Contractor shall provide PCP enclosure as specified on drawings.

B. Provide termination strips, interface hardware, wiring, cabling, and accessories necessary to complete operational interface between the PCP to MCCs, instrumentation, other field control panels, ancillary field devices, to complete system. Contractor shall provide and install enclosure for all wiring for connections between field devices, instruments located in a hazardous are and the PCP.

C. Wiring splicing is prohibited.

D. Provide control components including relays, timers, current loop isolators, and other equipment for interfacing and/or interlocking between motor starters, and associated protective circuits, and other type of control circuit function applicable to a particular final control element wired into applicable panel.

E. Refer to Specification 16745 SCADA RTU, coordinate PCP/RTU testing.

F. Analog signals received from field at panels shall be 4-20 mA DC signals.

1. Furnish signal conversion necessary for compatibility with panel mounted instruments and interface to digital process control system.

G. SCADA RTU Wiring Identification.

1. Identify and label field wiring originating from Pump control panel to SCADA RTU enclosures, field device and/or other enclosures.

MATERIALS

Electrical Wiring 240/120VAC power circuits shall be No.12 AWG minimum, copper, stranded (7 strands minimum) THHN, 600V covered in a polyvinyl chloride (PVC) insulation with a nylon jacket.

The color of conductors for different voltage systems shall be as follows:

240/120VAC

Single Phase

208/120VAC

Three Phase

480/277VAC

Three Phase

Control Wiring

1. Referring to Specification 19745 Section 2.2.A Power Wiring: AWG CU stranded THHN:

a. Field wiring for PCP monitoring and control I/O utilizing (120 VAC) input and output wiring: 14 AWG CU stranded THHN (7 strands minimum).

b. Field wiring for PCP monitoring and control I/O utilizing (24 VDC) input and output wiring: 14AG CU stranded THHN (7 strands minimum).

2. Additional guidelines:

a. Provide home runs from device’s terminal blocks to field devices and other enclosures with no intermediate connections or splices unless specifically shown on plans.

b. Intended and designed for use with 24 VDC or less are considered low voltage.

c. To prevent electrical interference and provide isolation from higher voltages, all low voltage wire shall be installed in separated and dedicated rigid conduit or cable trays that provide segregation.

Control Components

1. As shown on PCP Drawings provided by the Commission.

PART 2 EXECUTION

2.1 GENERAL

A. Notify the Engineer after the following items are complete to initiate installation of the PCP.

1. Permanent power is installed and operational

a. All field and power equipment required for PCP operation are installed

b. All conduit and wiring is installed to the PCP B. Storage all equipment and materials in dry, covered, ventilated location.

2.2 INSTALLATION

A. Protect equipment again physical damage.

B. Contractor shall install the enclosure, identify the wiring and terminate power, field and SCADA RTU wiring on terminal block, as specified on drawings.

C. Provide permanent labels on terminal points.

2.3 FACTORY TESTING.

A. Equipment: Inspected and tested prior to being shipped to field.

B. Each piece of hardware: Energized and tested to verify components function following manufacturer specifications.

C. Factory testing: Include integrated system test to demonstrate proper functioning of Red Lion process panel meter & analog output module, relay, selector switch, breakers, and I/O modules. Conduct test using minimally configured system.

Digital Inputs: Jump each digital input field terminal to 120VAC or 24VDC, according to module type. Observe change of state at console.

Digital Outputs: For relay output modules with field connections to both line and load, force each output on at the console and measure the change of state at field terminals with continuity tester. For relay output modules connected to interposing relays on PCP, verify proper output voltage and operation of interposing relays.

Analog Inputs: Introduce 4 to 20 mA DC signal at field terminal and observe changing value at console. Test response at 4 mA, 12 mA and 20 mA.

Analog Outputs: Force each output at console with values corresponding to 4 mA, 12 mA and 20 mA, and measure results at field terminals.

F. Provide 5 working days’ notice prior to starting factory testing. WSSC will typically witness testing in person or virtually but may waive this requirement on case-by-case basis.

G. Patent defects in equipment: Repaired or replaced, as required, at no cost to the Commission, until substantial completion.

1. If Latent defects are found notify the Commission immediately.

H. Any factory modifications to PCP must be approved, tested, and documented prior to final acceptance.

2.4

2.5 FIELD TESTING

A. Through the field test, the contractor ensures that all equipment is mounted, wired, and calibrated properly and ready for testing. Test control wiring from each field devices such as switches, instruments, and other equipment through the panels to each terminal block.

B. Preliminary test

1. Prerequisites

a. Verify that there is no visible corrosion or mechanical damage to PCP and associated equipment.

b. Verify valves operate correctly.

c. Verify PCP is installed, and power and control wires are terminated and labeled.

2. Preliminary test

a. Performed by the Contractor

b. Verify equipment has been mounted and wired properly; and PCP and associated equipment including limit switches, instrumentation (level transmitter, float switches, etc), drives, MCC’s, motor starters and motor/pump protections. Verify all wires are correctly terminated and labeled.

c. Test power and control circuits for continuity, short circuit and grounds faults.

d. Perform test to stablish electrical power to/from PCP and associated equipment (instrumentation, valves, drives, MCC’s, motor starters and motor/pump protections). Check all connected power feeds for proper operation and in accordance with contract and approved contract drawings and manufacture requirements.

e. Verify PCP and associated electrical equipment (MCC, panel board, valves, etc) and instruments (level and flow transmitters, float switches, etc) are correctly labeled in accordance with contract and approved contract drawings.

f. Verify that wire/conductor test for pumps and associated equipment have been performed and approved.

g. Verify that mechanical test for pumps and associated equipment have been performed and approved.

h. Calibrate and test instrumentation associated to PCP.

C. Field test

1. Prerequisites

a. Correct punch list items from Preliminary Test.

b. Notify Engineer 10 days prior to schedule Process Control Division to assist the Contractor on PCP Moore controllers (SPA2ISs’), timer’s configuration.

c. Contractor to coordinate with the Commission the field test schedule, Commission shall witness the test.

2. Field test

a. Verify all control and power circuits connected to PCP and associated equipment are energized.

b. Demonstrate instrumentation associated with PCP has been calibrated/tested and ready for commissioning.

c. Bump motors to verify correct rotation. Test motors.

d. Coordinate with

e. Verify operation of PCP, as a minimum verify the following:

1) Turn OFF power to motors and perform the following test at the PCP:

a) Verify wet well reading at Level transmitter, PCP wet well level display and display analog output signal to SCADA RTU PLC.

b) Verify LOW- LEVEL BYPASS switch is in OFF position and the LOW LOW-LEVEL BYPASS pilot light is OFF.

c) Manually activate HIGH, LOW and SANITARY SEWER OVERFLOW float switches at the wet well, verify the following:

(1) HIGH, LOW and SANITARY SEWER OVERFLOW pilot lights are ON

(2) HIGH, LOW and SANITARY SEWER OVERFLOW to SCADA RTU PLC relay contacts are closedactivated.

d) Manually deactivate HIGH, LOW and SANITARY SEWER OVERFLOW float switches at the wet well, verify the following:

(1) HIGH, LOW and SANITARY SEWER OVERFLOW pilot lights are OFF

(2) HIGH, LOW and SANITARY SEWER OVERFLOW to SCADA RTU PLC relay contacts are de-activated.

e) Set LOW LEVEL BYPASS switch to ON OFF position, manual activate LOW LEVEL float switch at wet well, verify the following:

(1) WET WELL LOW-LEVEL pilot light at PCP is ON

(2) LOW LEVEL BYPASS pilot light at PCP is OnOFF

(3) PUMPS LOW-LEVEL INTERLOCK at pump are open

(4) LOW LEVEL ALARM TO SCADA RTU PLC relay contacts are openactivated.

f) Set LOW LEVEL BYPASS switch to ON position, manual activate LOW-LEVEL float switch at wet well, verify the following:

(1) WET WELL LOW-LEVEL pilot light at PCP is ON

(2) LOW LEVEL BYPASS pilot light at PCP is ON

(3) LOW LEVEL BYPASS Timmer is timing and:

· PUMPS LOW LEVEL INTERLOCK at pump are close and

· LOW LEVEL ALARM TO SCADA RTU PLC relay contacts are activated.

(1) When the LOW-LEVEL BYPASS Timmer timeout confirm the following:

· PUMPS LOW LEVEL INTERLOCK at pump are open and

· LOW LEVEL ALARM TO SCADA RTU PLC relay contacts are de-activated.

b)

(1) Set LOW LEVEL BYPASS switch to OFF position

(2) Verify LOW LEVEL ALARM TO SCADA RTU PLC relay contacts are closed.

(3) Verify wet well reading at Level transmitter, PCP wet well level display and display analog output signal 4-20mA measurement on wires to be connected to SCADA RTU.

2) Turn ON power feeders to pumps and associated equipment, verify operational conditions of site for pump operation. All pumps and associated equipment (motor starters, MCC, motor/pump protections) and instrumentation (level transmitter, flow meter, float switch) are ready for operation. Perform the following test at the PCP:

2-PUMPS APPLICATIONS - LEAD / LAG

a) Set the LEAD/LAG selector switch to 1/2 – Pump 1 LEAD and Pump 2 LAG.

(1) Verify LEAD PUMP CONTROL relay is energize when level on the wet well level transmitter reach the START LEAD PUMP level, at that point check the following:

(a) LEAD Pump 1 starts.

(b) Verify Pump 1 is running.

(c) Verify Flow reading at the flow meter, PCP display and at STATION FLOW TO SCADA RTU analog output terminals.

(2) If level on the wet well increase to START LAG PUMP level, the LAG PUMP CONTROL relay will energize, at this point check the following:

(a) LAG Pump 2 starts.

(b) Verify LEAD AND LAG pumps 1 & 2 are running.

(3) If level on wet well increase to level transmitter HIGH-LEVEL ALARM value, the HIGH-LEVEL ALARM relay and the WETWELL HIGH-LEVEL pilot light energize. The HIGH ALARM relay contacts energize both pumps STOPGAP timers and the LEAD and LAG Pump 1 and 2 start. When the HIGH-LEVEL ALARM relay de-energizes, the LAG PUMP STOPGAP timer reset and the LAG Pump 2 stops. The LEAD pump continuous running until the LEAD PUMP STOPGAP timer timeout or LOW-LEVEL interlock contact opens.

(4) Level transmitter HIGH- and LOW-LEVEL ALARMS are backed-up through HIGH and LOW float switches installed at the wet well. Float switches circuits and associated DEBOUNCE timers start and stop the LEAD and LAG pumps. Disconnect the level transmitter and test the pump operation through the float switches control circuits.

(a) Activate the HIGH-LEVEL float switch. Verify:

· HIGH-LEVEL ALARM relay and the HIGH-LEVEL pilot light energize after HIGH-LEVEL FLOAT DEBOUNCE timer timeout (30 Sec, adjustable).

· LEAD and LAG Pumps 1 and 2 shut down.

(b) Activate LOW-LEVEL float switch. Verify:

· LOW-LEVEL ALARM relay and the LOW-LEVEL pilot light energize after the LOW-LEVEL FLOAT DEBOUNCE timer timeout (30 Sec, adjustable).

(5) LEAD and LAG Pumps 1 and 2 shut down. Reconnect the level transmitter and verify wet well reading at Level transmitter, PCP wet well level display and display analog output signal to SCADA RTU PLC.

(6) Verify flow meter reading at flow transmitter, PCP display and flow analog output TO SCADA RTU are the same.

b) Set the Lead/Lag selector switch to 2/1 – Pump 2 LEAD and Pump 1 LAG. Repeat steps (1) through (4) above.

3-PUMPS APPLICATIONS - LEAD / LAG

c) Set the LEAD/LAG selector switch to 1/2/3 – Pump 1 LEAD, Pump 2 LAG, Pump 3 Standby.

(1) Verify LEAD PUMP CONTROL relay is energize when level on the wet well level transmitter reach the START LEAD PUMP level, at that point check the following:

(d) LEAD Pump 1 starts.

(e) Verify Pump 1 is running.

(f) Verify Flow reading at the flow meter, PCP display and at STATION FLOW TO SCADA RTU analog output terminals.

(2) If level on the wet well increase to START LAG PUMP level, the LAG PUMP CONTROL relay will energize, at this point check the following:

(c) LAG Pump 2 starts.

(d) Verify LEAD AND LAG pumps 1 & 2 are running.

(3) If level on wet well increase to level transmitter HIGH- LEVEL ALARM value, the HIGH LEVELHIGH-LEVEL ALARM relay and the WETWELL HIGH- LEVEL pilot light energize. The HIGH ALARM relay contacts energize both pumps STOPGAP timers and the LEAD and LAG Pump 1 and 2 start. When the HIGH LEVELHIGH-LEVEL ALARM relay de-energizes, the LAG PUMP STOPGAP timer reset and the LAG Pump 2 stops. The LEAD pump continuous running until the LEAD PUMP STOPGAP timer timeout or LOW LEVELLOW-LEVEL interlock contact opens.

(4) Level transmitter HIGH and LOW LEVELHIGH- and LOW-LEVEL ALARMS are backed-up through HIGH and LOW float switches installed at the wet well. Float switches circuits and associated DEBOUNCE timers start and stop the LEAD and LAG pumps. Disconnect the level transmitter and test the pump operation through the float switches control circuits.

(c) Verify LEVEL SENSOR FAULT pilot light and relay energize, verify LEVEL SENSOR FAULT TO SCADA RTU PLC relay contact closes. Verify transmitter fault by disconnection the transmitter field wires to the PCP Level Controller.

(d) Activate the HIGH LEVELHIGH-LEVEL float switch. Verify:

· HIGH- LEVEL ALARM relay and the HIGH LEVELHIGH-LEVEL pilot light energize after HIGH- LEVEL FLOAT DEBOUNCE timer timeout (30 Sec, adjustable).

· LEAD and LAG Pumps 1 and 2 shut down.

(e) Activate LOW- LEVEL float switch. Verify:

· LOW- LEVEL ALARM relay and the LOW LEVELLOW-LEVEL pilot light energize after the LOW LEVELLOW-LEVEL FLOAT DEBOUNCE timer timeout (30 Sec, adjustable).

· LEAD and LAG Pumps 1 and 2 shut down.

(5) Reconnect the level transmitter and verify wet well reading at Level transmitter, PCP wet well level display and display analog output signal to SCADA RTU PLC.

(6) Verify flow meter reading at flow transmitter, PCP display and flow analog output TO SCADA RTU are the same.

d) Set the Lead/Lag selector switch to 2/1/3 – Pump 2 LEAD, Pump 1 LAG, Pump 3 stand by. Repeat steps (1) through (4) above.

e) Repeat Step b) for all (6) pumps combinations.

D. Perform SCADA RTU Field Testing in accordance with Section 16745.

**WSSC**

May December 20242025

Dec 29, 2014