Awtrp BHCRP App F

Project Test Plans Preparation Guide
Advanced Wastewater Treatment Plant
Sacramento Regional County Sanitation District
Version 1.0
September 2012
This page intentionally left blank
Contents
1.0 Introduction........................................................................................................................................1-1
1.1 Relationship with Other District Design Standards ........................................................................................ 1-1
2.0 General................................................................................................................................................2-1
3.0 Project Test Plans Preparation............................................................................................................ 1
3.1 Description..........................................................................................................................................................1
3.2 Test Plan Identification .......................................................................................................................................1
4.0 Pre-Operational Testing ....................................................................................................................4-1

4.1 Functional Checkout ....................................................................................................................................... 4-2
4.2 Performance Test ............................................................................................................................................ 4-2
5.0 Operational Test Plan Preparation ..................................................................................................5-1

5.1 48-hour Test.................................................................................................................................................... 5-1
5.2 10-day Operational Test.................................................................................................................................. 5-2
5.3 30-day Reliability Test Plan ........................................................................................................................... 5-2
6.0 Test Plan Examples............................................................................................................................6-1

7.0 Schedule ..............................................................................................................................................7-1
Appendices
Appendix A. Functional Checkout Form Example
Appendix B. Performance Test Form Example
Appendix C. 48-Hour Pre-Operational Test Plan Example
Appendix D. 10-Day Operational Test Plan Example
Appendix E. 30-Day Reliability Test Plan Example

Z:\00. Program Management\B4.01 - Engineering Standards Update\02 Work Products Archive\B4.01.01 - Project Test Plans Preparation Guide\Old\Final DRAFT - Project Test
Plans Guide v1.0.docx
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1.0 Introduction
The purpose of this Project Test Plans Preparation Guide is to establish an understanding of
content requirements for Designer-produced Test Plans for Sacramento Regional County
Sanitation District (District) projects under the Advanced Wastewater Treatment Plant (AWTP)
Program.
1.1 Relationship with Other District Design Standards

This document is one component in a suite of District Design Standards. The standards are
created and maintained in order to provide consistency and efficiency among design projects
within the District. The standards clearly document requirements, issues, decisions, products,
procedures, etc. that have reached general consensus of District staff.
Each component of the standards is targeted for a specific purpose. The purpose of this
document is as stated above. The components of the District Design Standards include:
x
Design Contract Requirements Presents the content requirements for contract

documents prepared for design projects.
Design Guidelines Describes discipline-specific District design preferences above

and beyond applicable codes and standards.
Guide Specifications A library of technical specifications available for project use.
CAD/BIM Standards Standards to be used on computer aided drafting (CAD)

drawings and Building Information Model (BIM) requirements for data and file
management.
Standard Drawings and Typical Details A library of CAD drawings common across
all projects and typically used details available for use by the Designer.
Project Test Plans Preparation Guide Describes the level of effort the District
requires of the Design Engineer to develop plans for subsequent use and implementation
by the Contractor during facility commissioning and startup.
Operations Manual and Training Development Guide Standards to follow in the

preparation of operations manuals and O&M training programs for the District.
Additional requirements related to design execution, deliverables, and designer coordination

with the AWTP Program Management Office (PMO) and District staff will be contained in the
Request for Proposal (RFP) for the specific design project. Particular reference is made to the
Reliability-Centered Design (RCD) process to be implemented on projects involving treatment
facilities and related equipment. Performance characteristics for testing and measurement will
largely be identified during the RCD workshops outlined in each project-specific RFP.
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2.0 General
This document provides the Design Engineer with guidelines for preparing the Project Test
Plans to be used during the Commissioning Phase of the project (i.e., commissioning and
startup). The Project Test Plans will include Pre-operational (PREOP) testing and Operational
Testing (OP TEST). The completed Project Test Plans will be provided as part of the Contract
Documents and must conform to District standards.
PREOP testing includes all testing conducted during construction and is located in the technical
specifications. PREOP testing must be strictly documented to ensure all tests were performed,
witnessed, and resulted in the desired outcome. All PREOP testing must be completed and
documented to the satisfaction of the District prior to starting the OP TEST. OP TEST
requirements are located in District Guide Specification Section 01 79 00 Commissioning and
lists all the PREOP tests, including any special sub-system tests, and describe the exact
requirements of the OP TEST, including the OP TEST schedule of activities.
The Design Engineer shall prepare for inclusion into the Contract Documents the Project Test
Plans for subsequent use and implementation by the Contractor during facility pre-operational
testing, commissioning, and startup. Test plans will be as detailed as possible without
knowledge of the specific equipment that will be installed. The Design Engineer also shall
prepare a schedule of all activities identified in the OP TEST for inclusion in the Appendix in
the contract documents -Test Plan. This schedule will be prepared with the knowledge that
specific dates will change as construction progresses. It will be the responsibility of the
Contractor to ensure this schedule is kept updated and to provide the District daily and threeweek look-ahead schedules. The Contractor also will follow the required protocol in notifying
the District of all test activities. The Design Engineer is responsible for preparing an initial
schedule and for detailing notification protocols in the Project Test Plans.
The purpose of including the Project Test Plans in the Construction Documents is to make the
Contractor aware of the specific level of effort the District requires to document equipment and
system preparedness after construction and to ensure the Contractors bid price includes
provisions for carrying out the detailed test procedures that must be followed prior to
commissioning and startup of all or part of the facility. The Project Test Plans prepared by the
Design Engineer will be included in the Contract Documents as an appendix to the Technical
Specifications, Section 01 79 00 Commissioning. In addition, the Design Engineer must
recognize the level of effort needed to prepare the Project Test Plans. The Design Engineer
must submit an outline of the Project Test Plans as part of Design Submittal No. 1 (DS-1), a
draft must be included as part of DS-2, and the draft final must be included as part of DS-3. The
final Project Test Plans will be submitted by the Design Engineer for approval after all
mechanical, electrical, and instrumentation equipment submittals have been approved.
The Project Test Plans will include a section detailing the requirements that all commissioning
and startup personnel will follow coordinating necessary activities with the District through the
Districts Commissioning Coordinator. These activities include, but are not limited to, proper
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planning, scheduling, and notification procedures, access requests, and shutdown/tie-in
procedures.
The Project Test Plans will include a section detailing all safety procedures that must be
complied with during commissioning and startup activities. This will include, but not be limited
to, discussion on proper personal protective equipment, lockout/tag-out procedures, and other
District-required safety programs.
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3.0 Project Test Plans Preparation

The Design Engineer shall prepare the Project Test Plans for subsequent use and
implementation by the Contractor as part of commissioning and startup. Project testing is
required to ensure all mechanical, electrical, and instrumentation equipment provided or
installed in association with the various stages of Work comprising the Project have been
stored, maintained, assembled, serviced, aligned, connected, calibrated, and adjusted in
accordance with the Construction Documents and the manufacturers recommendations prior to
being placed into service. Project testing shall be divided into two distinct stages: PREOP
testing and the OP TEST. The OP TEST cannot begin until the PREOP testing is completed
and documented to the satisfaction of the District.
3.1 Description
The Districts PMO will be responsible for maintaining the Master Test Log of all forms
required to document all Project testing. Requirements of the Design Engineer to record the
mechanical, electrical, or instrument unit description and equipment numbering are described in
the Districts Design Contract Requirements. The completed forms required for all tests will
include item description and equipment numbers, test description, date, data collected,
observations, and the legible full name and initials of representatives of the manufacturer,
Contractor, and District witnessing the testing. In addition, each test report form will include
records of the manufacturer, common functional description, model number, and serial number
of equipment used during the test for any purpose including, but not limited to, measurement,
monitoring, analytical analysis, etc. Example report forms are provided in the attached
appendices.
Data entry fields in the electronic test forms will be linked to the process and instrumentation
diagram (P&ID) drawings via a structured query language (SQL) server database so there is
only one location to add, delete, or modify testing data and equipment information. Refer to the
Districts CAD/BIM Standards for additional information.
Each installation test procedure and associated report form will be assigned a procedure number
with a prefix consisting of the governing specification section and a unique alpha or numeric
suffix. Installed piping test procedures are assigned numbers with a prefix consisting of the
governing specification section and piping system number with a unique alpha or numeric
suffix. For multiple equipment items, a numeric suffix is added following the alphabetic suffix
(e.g., 46 24 23C1, 46 24 23C2, etc.).
3.2 Test Plan Identification

Identify each test plan by using the associated equipment specification number plus an
alphabetic suffix as follows:
Factory Tests
Delivery Acceptance Tests
B
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Pre-operational and Start-up Checkout
Performance Test
48-hour pre-operational test plan
10-day operational test plan
30-day reliability test plan

September 24, 2012
4.0 Pre-Operational Testing

All PREOP testing requirements will be detailed in the Project Test Plans prepared by the
Design Engineer and shall be included in the Contract Documents. All PREOP test forms shall
be located and numbered sequentially with the technical specification sections or included per
discipline as an appendix to the Project Technical Specifications, Section 01 79 00
Commissioning. District Guide Specifications include the standard PREOP test forms, but these
shall be supplemented by the Design Engineer as necessary to accommodate any specific
requirements in the Project. Factory testing, performance testing, functional checkouts, vendor
system startup, and sub-system testing are included under PREOP testing. Factory testing shall
be specified in the technical specification section to which it applies and include the required
performance for a successful test, method of simulation, and test sheet. Factory testing also
shall include timing requirements for fixing a failed test and resuming or aborting and
rescheduling factory testing. Performance testing also shall be specified in the technical
specification section to which it applies and include the required performance for a successful
test, method of simulation, and test sheet. If substantial temporary construction is required to
conduct any performance test, that temporary construction shall be detailed on the construction
drawings provided in the Contract Documents.
Mechanical and HVAC PREOP testing includes: equipment manufacturers installation and
start-up certification, pump and fan functional checkout, sound and vibration tests, air balance
test, piping and valve vapor or liquid leakage tests, pipe cleaning, flushing and disinfection
tests, and, where required, performance testing of individual equipment (e.g., pump capacity
versus total dynamic head). Electrical PREOP testing includes: NETA testing of electrical
equipment, conductor and cable tests, motors larger than 50 Hp insulation tests, luminaire
switching and receptacle rotation and polarization tests. Control PREOP testing includes:
instrument calibration and testing, digital control and logic end-to-end tests, analog loop endto-end tests, and loop tuning. Other PREOP tests included in the Project Technical
Specifications include: earthwork and paving compaction tests; concrete and masonry strength
tests; coatings thickness tests; tank and structure leakage tests; etc.
PREOP and start-up activities associated with the various stages of Work comprising the
Project testing shall be detailed by the Design Engineer for inclusion in the Construction
Documents (i.e., Specifications). PREOP testing shall be carried out on all mechanical,
electrical, and instrumentation and control equipment, and all the associated items including
major pipelines, civil structures, and buildings.
The PREOP test plans prepared by the Design Engineer must include the following elements
where applicable:
1. Review of completed Functional Testing forms to verify that the item to be tested
and all associated equipment and appurtenances have successfully completed
functional checkout testing.
2. Pre-operation lubrication
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3. Setting and testing of all protective, control, and auxiliary devices. Required settings
and operation of all these devices shall be verified and functionally tested; trip
points shall be measured, adjusted, calibrated, and recorded upon both increasing
and decreasing process variable. Tests using simulated input or output signals will
not be acceptable to satisfy this requirement. Use of input or output signals may be
approved by the Districts representative if equipment damage would result from
using the actual process variable.
4. Equipment shall not be operated prior to the completion of the pre-operational and
start-up checkout.
The Functional Checkout and Performance Test that are conducted as part of PREOP testing
are discussed below.
4.1 Functional Checkout

Functional Checkout forms prepared by the Design Engineer must include the following
elements where applicable:
1. Every item shall be uniquely tagged per District auto-numbering tagging convention
and entered into the Districts Asset Management System before Functional
Checkout.
2. Every item shall be tested, and the results documented and confirmed, to ensure
correct alignment, balancing, and rotation.
3. Every manual and actuated valve shall be tested, and the results documented and
confirmed, under normal system conditions to ensure correct operation. This shall
include the setting of torque and limit switches where appropriate.
4. Every instrumentation loop shall be tested, and the results documented and
confirmed, to ensure correct operation.
5. Every item shall be functionally tested, and the results documented and confirmed,
to ensure "Manual Control" and "Remote Automatic Control," and "Automatic
Control" functions.
6. Every signal and alarm shall be tested (by simulation if necessary), and the results
documented and confirmed, to ensure correct operation.
7. All processes shall be demonstrated, and the results documented and confirmed, to
have been erected correctly and adjusted in accordance with the manufacturers
recommendations.
An example of a Functional Checkout test form is included in Appendix A.
4.2 Performance Test

Performance test forms shall be prepared by the Design Engineer for inclusion in the
Construction Documents; the forms shall be located and numbered sequentially with the
appropriate equipment specification sections or included per discipline as an appendix to the
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Project Technical Specifications, Section 01 79 00 Commissioning. An example of a
Performance test form is included in Appendix B.
Performance testing of systems shall be conducted in two stages: (1) each individual
component shall be performance tested, and (2) after each component has successfully
completed performance testing, the system shall be performance tested as a whole. The
performance test plans prepared by the Design Engineer, therefore, must confirm the intended
performance of individual items of equipment and the entire system as applicable:
x
Performance test procedures must be designed to verify that the equipment and
systems meet the intent of the Design Engineer and the manufacturers performance
claims included in the equipment and O&M submittals.
Process water, the origin of which (e.g., primary effluent, secondary effluent, filter
effluent, etc.) will be identified by the Design Engineer in the Project Test Plans,
shall be used for the performance testing of all liquid systems. Excluded from this
requirement are gaseous, oil, and chemical systems which will be tested using the
intended fluid or a compatible substitute subject to Districts approval.
Performance test procedures will include the measurement of all operating

parameters as specified in the appropriate equipment specification section or in an
appendix to the Project Technical Specifications, Section 01 79 00
Commissioning. The Design Engineer must identify in the performance test plan the
operating parameters to be measured and the criteria that define successful
performance.
In the Project Test Plans, the Design Engineer must describe the quantities of
process water to be used during performance tests, how the process water will be
introduced into the system or sub-system being tested, how the process water will
be disposed of and how the system or sub-system will be cleaned after the test, and
how all of these activities will be coordinated with the District.
Equipment shall be operated for a sufficient period of time to observe and record
machine operating and performance characteristics including, but not limited to,
noise, temperature, and vibration. Key performance characteristics measured during
performance testing will be identified during the Reliability Centered Design
Workshops conducted with District staff during design.
The Design Engineer will identify in the performance test plan specific procedural
steps to be taken to verify that all associated control and instrumentation systems
function properly under actual operating conditions; tests using simulated input or
output signals will not be acceptable to satisfy this requirement.
The Design Engineers performance test plan will include steps to be taken after
performance testing to check tested equipment for loose connections, unusual
movement, or other indications of improper operating conditions and/or
characteristics. Any deficiencies so noted shall be corrected to the satisfaction of the
Districts representative.
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5.0 Operational Test Plan Preparation

Design Engineer shall prepare Operational Test (OP TEST) Plans to verify that the individual
components function together properly as a system using reclaimed water. The Design
Engineers OP TEST Plan will include verification that a District representative has certified
that all Installation Tests have been successfully completed and a Certificate of Occupancy,
signed by the Consumes Fire District Fire Marshall, has been submitted. The Design Engineers
OP TEST Plan will include steps to be taken to fill all process systems to be tested, except
those using domestic water, oil, air, or chemicals, with plant effluent water. All domestic water,
oil, air, and chemical systems shall be filled with the specified fluid. Upon completion of the
filling operations, the Design Engineers Operation Test Plan shall describe how the operation
test will commence within 12 hours.
The OP TEST Plan prepared by the Design Engineer will accommodate the execution in three
distinct stages: (1) 48-hour test, (2) 10-day Operational test and (3) 30-day Reliability test. The
stages are described below.
5.1 48-hour Test

The 48-hour Test Plan shall be prepared by the Design Engineer for inclusion in the
Construction Documents. The 48 hour testing shall be carried out only after successful
completion, and documentation of all PREOP testing. The purpose of the 48-hour Test is to
circulate water through the completed facility for a period of not less than 48 continuous hours,
during which all parts of the system shall be operated as a complete facility at all possible
hydraulic loading conditions, as directed by the District and detailed by Design Engineer. The
Design Engineers 48-hour Test Plan will provide a means of documenting and verifying that
the Contractor shall operate all equipment during the 48-hour Test while being responsible for
performing all preventative maintenance and recording all performance and operational data
identified by the Design Engineer. In addition, the 48-hour Test Plan, prepared by the Design
Engineer, shall include:
1. Skills requirement for all personnel operating equipment during the 48 hour preoperational testing.
2. Draft Operations and Maintenance requirement for use by Contractor during 48hour Pre-operational Testing.
3. Schedule for implementing the testing of the overall system performance including
accurate flow measurement, accurate flow split, and achieving maximum and
minimum design flows.
4. Reference to all report forms required to record all operating parameters for each
individual component at each loading condition to be tested.
5. Mechanism for confirming and documenting successful completion of the 48-hour
Pre-operational Test
An example of a 48-Hour Test Plan and associated forms are included in Appendix C.
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5.2 10-day Operational Test
The 10-day Operational Test Plan shall be prepared by the Design Engineer for inclusion in the
Construction Documents. Each system must operate at its average design range for 240
consecutive hours under automatic and manual control. The Design Engineers Operational
Test Plan will reflect that the 10-day Operation Test will not begin on Fridays, weekend days,
holidays, or on a day before a holiday. The District will operate all equipment and record all
data during the 10-day Operational Test. The Contractor will maintain all equipment during this
test period. In addition, the Contractor shall provide a minimum of one skilled, experienced
equipment start-up specialist, preferably a California certified operator, during dayshift to assist
in equipment operation, record data, and troubleshoot problems. The Design Engineers
Operational Test Plan will reflect the fact that this specialist shall be assigned only to this task
during this test period.
The Operational Test Plans, prepared by the Design Engineer, shall include the following
details regarding the 10-day Operational Test:
1. Contractor requirements including the required number of skilled experienced
equipment start-up specialists to assist in equipment operation, data recording and
troubleshooting during the test period.
2. Training requirements for all District personnel operating equipment during the 10
day-operational testing.
3. Draft Operations and Maintenance Manuals requirement for use by District
personnel during 10-day operational testing.
4. Description and method for the diversion of flows into new treatment units.
5. Requirements and set-points for all operational parameters.
6. Compliance checklist for authorization and agreement by the District on diverting
wastewater to the new treatment units.
7. Report form to record all operating parameters for the facility.
8. Every equipment item shall be updated with operational and calibration details into
the Districts Asset Management System.
An example of a 10-Day Operational Test Plan and associated forms are included in
Appendix D.
5.3 30-day Reliability Test Plan

The 30-day Reliability Test Plan shall be prepared by the Design Engineer for inclusion in the
Construction Documents. This 30-day Reliability Test shall be carried out only after successful
completion of the 10-day Operational Test. 30-day reliability testing shall not begin until the
Engineer notifies the Contractor in writing that all installed and operational tests have been
successfully completed. Equipment manufacturer's installation certification forms shall be
submitted, prior to the beginning of any reliability tests as specified in this section.
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During the reliability test, all systems shall be operated by District under both maximum and
minimum design conditions.
The 30-day Reliability Test Plan, prepared by the Design Engineer, shall include:
1. Contractor requirements including the required number of skilled experienced
equipment start-up specialists to assist in equipment operation, data recording and
troubleshooting during the test period.
2. Training Requirements for all District personnel maintaining equipment during the
30 day-operational testing
3. Final Operations and Maintenance Manuals requirement for use by District
personnel during 30-day operational testing
4. Requirements and revised set-points for all operational parameters
5. Report forms to record all operating parameters for the facility
6. Mechanism for referring problems which cannot be resolved on-site to the Engineer
and mechanisms for implementing alternatives developed by the Engineer to correct
the problems.
7. Requirements for implementing the Performance Test Plans developed and
approved previously.
8. Mechanism for updating Operations and Maintenance Manuals with amendments,
additions or revisions.
An example of a 30-Day Reliability Test Plan and associated forms are included in
Appendix E.
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6.0 Test Plan Examples

The District maintains a library of Project Test Plan examples. The Design Engineer may refer
to the examples during the preparation of the Project Test Plan specific to the unit processes or
modifications to existing facilities for which the Design Engineer is responsible.
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7.0 Schedule
The Project Test Plans shall be prepared by the Design Engineer for inclusion in Design
Submittal No. 3 (DS-3) to the District. Also included in DS-3 will be the initial schedule for the
implementation of the various test plans.
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APPENDIX A
FUNCTIONAL CHECKOUT FORM
EXAMPLES
APPENDIX A
CONTRACT #
TEST NO:
Pump Function Checkout
EQUIPMENT #:
REF. DRAWING # (S)
MANUFACTURER:
MODEL #:
LOCATION:
SPECIFICATION #:
EQUIPMENT DESCRIPTION:
1.) Verify anchor bolts torque.

2.) Set alignment and balancing
Settings
A:
B:
C:
3.) Mechanical seals checked

4.) Mechanical equipment cleaned and flushed
5.) Protective devices set
Device Tag#
Description
Setpoint
Remarks
WITNESS BLOCK
Test Personnel:
Date:
Contractor Representative:
Date:
District Representative:
Date:
A-1
APPENDIX A
A-2
APPENDIX B
PERFORMANCE TEST FORM
EXAMPLE
APPENDIX B
CONTRACT # 4110
TEST NO: 11312D1: Rotary Lobe Positive Displacement Pumps
Performance Test
EQUIPMENT #:
REF. DRAWING # (S)
MANUFACTURER:
MODEL:
PUMP TYPE:
SPECIFICATION #:
All pre-operational tests must be performed prior to the performance test. Refer to pump spec and
manufacturer data for operating performance data. Provide all appropriate temporary piping and
fittings.
TEST RESULTS
Target
Capacity,
gpm
Actual
Capacity,
gpm
Upstream/
Downstream
Head, ft
Pressure
Loss, psi
Motor
Speed,
rpm
Phase
Voltage
Phase
KW
Motor
Temperature
COMMENTS
WITNESS BLOCK
Test Personnel:
Date:
Contractor Representative:
Date:
District Representative:
Date:
B-1
APPENDIX B
B-2
APPENDIX C
48-HOUR TEST PLAN
EXAMPLE
APPENDIX C
48-HOUR TEST PLAN
CONTRACT #4110
48-HOUR TEST WITH WATER
FOG/FPW Receiving Station
Objective: To perform a 48-hour wet test using water on the FOG/FPW Receiving Station to test
the strainer, grinder/rock trap, transfer/mixing pump, storage tank, feed pumps, associated valves
and piping.
Prior to pre-operational testing, make sure that all performance tests are completed.
FOG Receiving Equipment
1. Make sure that the strainer, grinder/rock trap, transfer/mixing pumps, storage tanks, feed
pumps, and associated valves are READY. The valves isolating the line to the MS lines
where the FOG/FPW will be fed should be closed and locked out.
2. Obtain the necessary cam lock connectors and connect a water truck to the offloading
connection and use reclaimed water available at the septage receiving station. Use the
transfer/mixing pump to automatically configure the valves and pump the water to the
storage tank. The pump and valves should switch to mixing mode after each truck load.
Multiple truck loads will be required so that the content of the water trucks exceeds the
capacity of the storage to observe high alarm and shutdown events.
3. Once the storage tank is full, disconnect the truck and observe the valve operation
changing to the mixing configuration.
4. Allow the storage tank to mix with the upper tank discharge point for 3 hours per day and
modify the valving to utilize the mid-point discharge for the remainder of the day.
5. Configure the valving to allow the feed pump to operate and fill the second storage tank
through one FOG/FPW line to the MS line and back through the other FOG/FPW line.
6. Observe the low level shut off.
7. Drain the content of the tank and repeat the process with the second FOG/FPW storage
tank.
8. After completion of the storage tank testing described in steps 1 through 7, drain the
content into the drain system.
9. Provide temporary piping water truck and related equipment as needed.
C-1
APPENDIX C
48-HOUR TEST PLAN
CONTRACT #4110
TEST NO. ____: FOG/FPW Receiving Station
48-Hour Test Report Form
Fill out separate form for each piece of equipment being tested.
EQUIPMENT #:
REF. DRAWING # (S)
MANUFACTURER:
MODEL:
SERIAL #:
EQUIPMENT SUBMITTAL #:
START OF TEST:
END OF TEST:
Provide lubrication for equipment as recommended by manufacturer prior to testing.
Date/Time
48-HOUR TEST CHECKLIST

Description of Test
Pass
Fail
CONTR.
INITIALS
ENGRS
WITNESS
COMMENTS
C-2
APPENDIX D
10-DAY OPERATIONAL TEST PLAN
EXAMPLE
APPENDIX D
CONTRACT #4110
10-DAY OPERATIONAL TEST WITH FOG
FOG/FPW Receiving Station
Objective: To perform a 10-day wet test using water on the FOG/FPW Receiving Station to test
the strainer, grinder/rock trap, transfer/mixing pump, storage tank, feed pumps, associated valves
and piping.
Prior to operational testing, make sure that all pre-operational tests are completed.
Date/Time
10-DAY OPERATIONAL TEST PREREQUISITES

Description of Test
Pass
Fail
CONTR.
INITIALS
Skilled experienced equipment
start-up specialists to assist in
equipment operation, data
recording and troubleshooting
during the test period
Training Requirements met for
all District personnel operating
equipment during the 10 dayoperational testing
All operational and calibration
characteristics for each item
entered into the District Asset
Management System
Set-points provided for all
operational parameters
Description and method for the
diversion of flows into new
treatment units provided
Report form to record all
operating parameters complete
Mechanism for problem
resolution prepared
Approval by SRCSD Operations
for diverting flows
ENGRS
WITNESS
D-1
APPENDIX D
FOG Receiving Equipment
PART ONE
1. Make sure that the strainer, grinder/rock trap, transfer/mixing pumps, storage tanks, feed
pumps, and associated valves are READY. The valves isolating the line to the MS lines
where the FOG/FPW will be fed should be closed and locked out.
2. Obtain the necessary cam lock connectors and connect a truck (FOG, FPW, or MS) to the
offloading connection. Use the transfer/mixing pump to automatically configure the
valves and pump the FOG, FPW, or MS to the storage tank. The pump and valves should
switch to mixing mode after each truck load. Multiple truck loads will be required so that
the content of the trucks exceeds the capacity of the storage to observe high alarm and
shutdown events.
3. Once the storage tank is full, disconnect the truck and observe the valve operation
changing to the mixing configuration.
4. Allow the storage tank to mix with the upper tank discharge point for 3 hours per day and
modify the valving to utilize the mid-point discharge for the remainder of the day.
5. Configure the valving to allow the feed pump to operate and fill the second storage tank
through one FOG/FPW line to the MS line and back through the other FOG/FPW line.
6. Observe the low level shut off.
7. Drain the content of the tank and repeat the process with the second FOG/FPW storage
tank.
8. After completion of the storage tank testing described in steps 1 through 7, remove locks
from the valves to the MS lines, pump content into the operational MS line.
9. Close tank valves and ensure isolation of the FOG/FPW tanks, and test the FOG/FPW
flushing with mixed sludge for 3 days.
10. Provide temporary piping, FOG, FPW, or MS truck and related equipment as needed.
PART TWO
1. Drain the content of either or both tanks.
2. Implement Control Strategy 1423.
D-2
APPENDIX D
CONTRACT #4110
TEST NO. ____: FOG/FPW Receiving Station
10-Day Operational Test Report Form
Fill out separate form for each piece of equipment being tested.
EQUIPMENT #:
REF. DRAWING # (S)
MANUFACTURER:
MODEL:
SERIAL #:
EQUIPMENT SUBMITTAL #:
START OF TEST:
END OF TEST:
Provide lubrication for equipment as recommended by manufacturer prior to testing.
Date/Time
10-DAY OPERATIONAL TEST CHECKLIST

Description of Test
Pass
Fail
CONTR.
INITIALS
ENGRS
WITNESS
COMMENTS
D-3
APPENDIX D
D-4
APPENDIX E
30-DAY RELIABILITY TEST PLAN
EXAMPLE
APPENDIX E
30-DAY RELIABILITY TEST

01660C7 MIXED SLUDGE FEED SYSTEM
GENERAL TEST PLAN
The reliability test for the MS feed system consists of placing in service the permanent MS feed control
system, each digester battery MS feed pump and associated automatic control system, and MS return
sludge flow control system. The District and Engineer will develop and implement a detailed start-up plan
to place the permanent mixed sludge feed system in service. The Contractor will be responsible for all
preventive and corrective maintenance of all mechanical, electrical and instrumentation equipment, fine
tuning instrumentation control loops, and cleanup if due to equipment or piping failure.
The temporary MS feed system will be placed out of service and the new MS feed system will be placed
in service. The MS feed system includes automatic speed control of all three digester battery MS feed
pumps, ratio control of the same MS feed pumps, automatic start;stop of the backup MS transfer pumps,
automatic start/stop of the MS booster pumps, automatic speed control of the
MS transfer pumps and MS booster pumps, automatic level control of the MS feed tank via the output of
all three digester battery MS feed pumps.
The MS feed pumps for two batteries will be placed in service in manual flow control. The MS feed
pumps for the other battery will be placed in service in automatic ratio flow control. Following fine tuning
and verification of automatic operation, the second battery will be placed in service in automatic control
and the same for the third battery. Concurrent to sequencing in service the automatic control of the MS
feed pumps, the MS transfer pump(s) will be placed in manual speed control and if required the MS
booster pump( s). After all three digester battery MS feed pumps have been debugged and readied for the
reliability test, the MS transfer pump/MS booster pump return sludge loop shall be placed in service. The
MS feed system shall be operated at loading rates as establish by the District. During the reliability test,
the Contractor shall put into service each standby MS feed pump to take the place of one duty MS feed
pump per Battery II and III digesters. The duration of operation of the standby MS feed pump will be
determined by the District.
E-1
APPENDIX E
Date/Time
30-DAY OPERATIONAL TEST PREREQUISITES

Description of Test
Pass
Fail
CONTR.
INITIALS
Skilled experienced equipment
start-up specialists to assist in
equipment operation, data
recording and troubleshooting
during the test period
Training Requirements met for
all District personnel
maintaining equipment during
the 30 day-operational testing
Final Operations and
Maintenance Manuals
requirement for use by District
personnel during 30-day
operational testing available
Revised set-points provided for
all operational parameters
Report form to record all
operating parameters complete
Mechanism for problem
resolution prepared
Mechanism for updating
Operations and Maintenance
Manuals prepared
Approval by SRCSD Operations
for starting test
ENGRS
WITNESS
E-2
APPENDIX E
30-DAY RELIABILITY TEST CHECKLIST
Date:
Day # of 30 day test:
System
Items to be Checked
Mixed Sludge Tank 1
Verify Level at LIT & LI

Verify High/Low Level Alarms
Verify overflow Alarm
Verify LIC 8551 Stability
Verify LIC 8551 Stpoint/Proc Var
Verify Level at LIT & LI
Verify High/Low Level Alarms
Verify overflow Alarm
Verify LIC 8551 Stability
Verify LIC 8551 Stpoint/Proc Var
Grinder Speed
Grinder Amp
Verify Local HS
Verify ACC HLS
Verify Grndr HI Press Alarm
Verify Grndr Diff Pres Alarm
Verify Grndr Jam Alarm
Verify Grndr Jam Shutdown
Grinder Speed
Grinder Amp
Verify Local HS
Verify ACC HLS
Grinder Speed
Grinder Amp
Verify Local HS
Verify ACC HLS
Pump Speed
Pump Flow
Pump Mtr Amp
Discharge Press
Suction Press
seal Water Flow
Verify Local HS
Verify ACC HLS
Grinder Speed
Grinder Amp
Verify Local HS
Verify ACC HLS
Mixed Sludge Tank 2
Primary Sludge Grinder 1

GDR83926

GDR83927

GDR83928
Mixed Sludge Tank

Circulating Pump 2
P83907
Mixed Sludge Tank

Grinder 1 GDR83924
Checked By
Problems
E-3
APPENDIX E
E-4

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Project Test Plans Preparation Guide

Advanced Wastewater Treatment Plant

Sacramento Regional County Sanitation District

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Project Test Plans Preparation Guide

4.0 Pre-Operational Testing ....................................................................................................................4-1

5.0 Operational Test Plan Preparation ..................................................................................................5-1

6.0 Test Plan Examples............................................................................................................................6-1

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

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Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

1.1 Relationship with Other District Design Standards

Design Contract Requirements Presents the content requirements for contract

Design Guidelines Describes discipline-specific District design preferences above

Guide Specifications A library of technical specifications available for project use.

CAD/BIM Standards Standards to be used on computer aided drafting (CAD)

Operations Manual and Training Development Guide Standards to follow in the

Additional requirements related to design execution, deliverables, and designer coordination

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

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Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

3.0 Project Test Plans Preparation

3.2 Test Plan Identification

Delivery Acceptance Tests

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

48-hour pre-operational test plan

10-day operational test plan

30-day reliability test plan

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

4.0 Pre-Operational Testing

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

4.1 Functional Checkout

4.2 Performance Test

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

Performance test procedures will include the measurement of all operating

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

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Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

5.0 Operational Test Plan Preparation

5.1 48-hour Test

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

5.3 30-day Reliability Test Plan

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

Sacramento Regional County Sanitation District

Project Test Plans Preparation Guide

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