Commissioning, testing and handover

Commissioning, testing and handover

From the first lighting of the equipment to proving the performance of the set

Commissioning is the process of converting an installed package into a usable system. At this stage, it should be determined how the equipment works in real conditions, whether the communication between them is correct or not, and to what extent the final result conforms to the defined project requirements.

Turning on the pump, water coming out of the nozzle and changing the color of the lights are the first signs of operation. Acceptance of the project requires more evidence: the quality of the display, the sustainability of the work, the consumption of resources, the performance of protections, the quality of water and the ability of the operator to manage the collection.

In the previous discussions, the conditions for entering the startup were reviewed. This chapter explains the order of tests, the method of recording results, and the route of acceptance and delivery.

The patterns and training numbers in this chapter must be adapted for each project to design documents, builders' instructions, contracts, and site requirements.

30–1. launch and adoption; Steps associated with different outputs

To avoid ambiguity, project status should be reported in clear terms.

Factory testing of equipment, if provided for in the contract, can provide part of the acceptance evidence. However, the effect of installation, piping, power supply and actual connection of the equipment should be checked at the project site.

In the introduction of OASE Professional services, installation, testing of components, loading of the display program and final settings, related setup steps are also introduced. OASE Professional installation service ^[205]

30–2. Preparation of the test order before the start

Each test must have a specific order before implementation. This command helps the team achieve a repeatable and arbitrable result.

The minimum required information is:

• Test ID and equipment range.

• Purpose and authority of acceptance.

• Implementation prerequisites.

• Initial status of valves, circuits and settings.

• Measuring tools and their installation locations.

• Test steps and required data.

• Stop conditions.

• Expected result and acceptance limits.

• How to restore the system to normal state.

• Responsible for implementation, witness and verification authority.

Clear target example

"Checking the height of the fountain" is a general term.

A more precise expression can be as follows:

"Measurement of the stable height of J-02 circuit fountains at the specified water level, with a specified arrangement of active circuits, under recorded wind conditions and comparison with the approved acceptance range."

The criteria must be determined before seeing the result. Changing the criteria after the test, if necessary, requires a technical review and recording of the decision.

30–3. Confirmation of readiness for the entry of water and electricity

Preparation should be specified for each section. The filter circuit may be ready, but the display circuit still needs modification.

Before the water enters, the cleanliness of the tank, drain paths, connections, valves, level sensors and equipment inside the pond are checked. Before electrification, installation and related preliminary tests must be completed.

The IEC 60364-6 standard deals with the initial and periodic inspection of low voltage electrical installations. Its use in the project must be accompanied by the specific requirements of the installation site and applicable regulations; The introduction page of this standard alone is not a complete test instruction. Official introduction of IEC 60364-6 ^[206]

In the startup program it should be clear:

1. Which part is energized or under pressure? 2. Who is responsible for controlling it? 3. What activities are allowed in the same area. 4. If needed, how to stop and isolate the energy.

Electrical tests must be performed by qualified persons with appropriate tools. The test method should also prevent damage to controllers, drives, power supplies and other sensitive equipment.

Figure 30–1 — Startup sequence

Suggested form: a diagram with the path "installation completion → readiness check → single equipment test → circuit test → integrated test → training and delivery". From each step, the path back to "Correcting and repeating the test" should be shown.

Subtitle: "The transition to the next stage is based on the recorded result of the previous stage."

30–4. Data measurement and validation tools

The result of the test depends on the quality of the measurement. The instrument should have a suitable range, accuracy and speed of response, and its calibration or verification status should be known.

Showing the number on the controller does not prove its correctness by itself. For example, the displayed pressure value should be adapted to the set range of the sensor and the reference instrument.

Also, the rate of data recording should be compatible with the speed of the event. Logging a value per minute is not appropriate for checking the short delay of a valve.

For each important reading, operating conditions are also recorded: number of active circuits, pump speed, water level, fluid status and environmental conditions.

30–5. Preparation of water and verification of operating conditions

The water used in the construction test may contain dust, material particles or contamination from prolonged standing. Before operation, cleaning and preparation of the circuit must be done according to the relevant program.

Decorative fountain and interactive fountain are not the same in terms of users' contact with water. The monitoring program and acceptance criteria should be appropriate to the actual use of the collection.

For decorative fountains, CDC emphasizes water management, cleaning and disinfection, and attention to sediment, biofilm, and water retention. This manual is a technical reference and should be adapted to the requirements of the project site. CDC Guidelines for Decorative Fountains ^[207]

In interactive water fountains, the readiness of the purification and disinfection system, monitoring and management of the complex must be checked before public use. CDC's guide to using water playgrounds ^[208]

In the startup file, the following are recorded:

• Water source and its initial condition.

• Cleaning operation done.

• Preparation of purification and injection equipment.

• Verification of related sensors.

• Measurement results and anticipated tests.

• Responsible for monitoring and necessary measures when exceeding the permitted limits.

The apparent clarity of water is not a sufficient criterion for sanitary acceptance. Also, an acceptable test result is not a substitute for a continuous water management program.

30–6. Initial setup of pumps and circuits

The initial setup should start from a manageable range and gradually expand.

Before the start of each pump, the conditions of installation, water supply, necessary ventilation, status of valves and preparation of the exit route are adjusted according to the instructions of the same equipment. Checking the direction of rotation should also be done with the approved method of the manufacturer; A method that does not lead to dry operation or equipment damage.

Once started, these symptoms are checked and recorded:

• Formation of stable flow.

• Pressure and flow appropriate to the work situation.

• Absence of unauthorized leakage.

• Abnormal sound and vibration.

• Power flow status and alerts.

• The behavior of the water level in the tank and pond.

• Performance of filters and return path.

Increasing the speed command must be done within the allowed range. Some equipment have minimum flow, speed or cooling restrictions; Therefore, starting from the lowest selectable value in the software is not always the right way.

After the initial acceptance of each circuit, its performance is checked in combination with other circuits.

30–7. Measuring the working point and efficiency of the pumping set

To evaluate the pump, recording the output pressure alone is not enough. Flow rate, total head and input power should be measured under the same conditions.

Between the two measurement sections in suction and discharge, the pump head is obtained from the following relationship:

$H=\frac{p_d-p_s}{\rho g}+\frac{v_d^2-v_s^2}{2g}+(z_d-z_s)$

In this regard:

• $H$ : Pump head, in meters.

• $p_d-p_s$: The difference between the pressure and the suction, in terms of pascals.

• $v_d$ and $v_s$: Average flow speed in the measurement sections.

• $z_d-z_s$ : Height difference of sections.

• $\rho$ : fluid density.

• $g$ : Gravitational acceleration.

For water, the power transferred to the flow is calculated from the following equation:

$P_{water}=\rho gQH$

Educational example

Suppose in a test:

• Measured flow rate: 18 cubic meters per hour.

• Total measured head: 16 meters.

• Actual input power upstream of the drive: 1.25 kW.

• Density of water for calculation: 1000 kg/m3.

Conversion rate:

$Q=\frac{18}{3600}=0.005m^3/s$

Power transferred to water:

$P_{water}=1000\times 9.81\times 0.005\times 16=784.8W$

Efficiency from electricity to water metering point:

$\eta =\frac{784.8}{1250}\times 100\approx 62.8\%$

This value includes the effect of equipment losses within the measurement boundary, including drives and motors. To compare with the efficiency listed in the catalog, the efficiency definition and the measurement limit must be the same. KSB technical reference also distinguishes between pump efficiency and pumping set efficiency. Definition of efficiency in KSB technical reference ^[209]

This example does not specify a minimum acceptable yield for fountains.

Figure 2–30—Measurement of pump performance

Suggested image: real photo of the test circuit, along with the mark of the place of measurement of suction and discharge pressure, flow rate and input power.

Subtitle: "The location of the measurements and the efficiency calculation boundary must be specified in the test report."

30–8. Comparison of the result with the acceptance criteria

The relative deviation of a measured value from the target value is calculated as follows:

$\mathrm{انحراف\; درصدی}=\frac{\mathrm{مقدار\; اندازه‌گیری‌شده}-\mathrm{مقدار\; هدف}}{\mathrm{مقدار\; هدف}}\times 100$

Educational example

Let's assume that the target flow rate of a circuit is 18 cubic meters per hour and for this example, the acceptance range is pre-determined as ±5%.

Acceptance range:

$17.1\le Q\le 18.9m^3/h$

If the measured flow rate is 17.3:

$\frac{17.3-18}{18}\times 100\approx -3.9\%$

This number is within the assumed range. However, the acceptance decision should also consider the measurement uncertainty and the adopted decision rule; Especially when the result is close to the border.

Acceptance of Dubai alone does not mean complete acceptance of the circuit. The total flow may be fine, but the distribution between the nozzles, the height of the fountain, or the quality of the water output does not match the design.

Acceptance limits for flow rate, height, pressure, sound and time delay should be determined separately and according to the importance of each feature.

30–9. Level test, water return, overflow and discharge

The test should show that the water has a predictable path under all expected conditions.

Important situations include:

• Starting a circuit and filling its pipes.

• Simultaneous start of authorized circuits.

• Stop showing and return water to the tank.

• Compensatory water function.

• Reaching the control thresholds.

• Overflow and drain function.

• Surface behavior in variable views.

In a dry fountain, the collection of water on the surface, the drainage of channels and the creation of local accumulation should be checked. In a pond fountain, splashing out of the design area and its effect on the surrounding paths are also important.

Interpretation of the level drop

A drop in water level is not necessarily equal to a leak. For analysis, compensation water, precipitation, discharge, washing, evaporation and spraying should be considered.

For a given boundary of the system:

$\Delta V=V_{ورودی}-V_{خروجی}$

Internal circulation circuits are not considered net inputs or outputs when they are completely within this boundary.

Volume measurement should be done in comparable situations; Because part of the water may be inside the pipes while working and inside the tank when stopping.

30–10. Adoption of lighting and water show and music

Acceptance of the show must be done at approved viewing points and recorded environmental conditions.

The review items include:

In order to measure coordination, it must be known which moment is being checked: sending the command, opening the valve, releasing the water or reaching the desired height of the fountain. These moments are not the same.

The test video should have a time reference and the location of the camera. The camera's automatic exposure and color adjustments can alter the judgment of the actual intensity or color of the light.

In its commissioning services, Crystal Fountains includes the final adjustment of the water movement and the training of the maintenance team in addition to the commissioning of the equipment. Crystal Fountains setup and training services ^[210]

Figure 30–3—Assessment from the Spectator's Point of View

Suggested image: plan of the fountain with three specific viewing points, along with a photo of the same moment of view from each point.

Caption: "Visual reception should be done based on specific viewing points and viewing conditions."

30–11. Test protections and error conditions

Performance testing should also cover system response to anticipated abnormal situations.

These tests are performed in a controlled manner. Valid input simulation can be used to check the protection logic if the design is suitable. The scope of such a test should be clear: simulating the signal does not fully prove the physical performance of the sensor itself.

For each test, four events are recorded:

1. Create a test situation. 2. Status detection by the system. 3. Execution of the expected action. 4. Controlled return to normal.

Seeing the warning message on the screen is not enough; The actual effect of the command on the equipment is also examined.

A fault must not result in pump dry-running, hazardous electrical contact, uncontrolled material injection, or other harmful condition. The test method must have solved these limitations in advance.

Once finished, all simulations, software coercions and temporary settings should be removed and normal status verified.

30–12. Integrated testing and stable operation

After the circuits are accepted, the actual operating combinations are checked.

The selection of scenarios should be based on the greatest pressure on different departments. One scene may use the most electricity and another scene may cause the most water backflow or splash.

Important scenarios can include:

• The maximum allowed combination of active equipment.

• Quick changes allowed display.

• Simultaneous work of display and refinement.

• Transition between display, quiet mode and pause.

• Repeated implementation of the daily program.

• Continue to work in the anticipated reduced state.

The duration of the stability test should be determined based on its purpose; For example, observing thermal behavior, surface fluctuation, error recurrence or water quality stability. A fixed duration, such as 24 or 72 hours, is not a general criterion for all fountains.

During the test, key data are recorded: pressure, flow, power, water level, alarms, environmental conditions and operator interventions.

For the energy consumption of a cycle, the following relationship can be used:

$E=\sum P_i{t}_i$

Powers must be real and specific time periods. The total rated power of the equipment does not represent the actual consumption of a variable display.

30–13. Fixing bugs, repeating tests and postponed tests

An unfavorable result should lead to specific action: diagnosis of the cause, correction, investigation of side effects and repetition of relevant tests.

If pump speed is changed to modify the height of a fountain, the effect on flow rate, power consumption, spray and response time is also investigated. Retesting should be proportional to the scope of the effect of the change.

The status of each test should be one of the following:

• Accepted.

• Rejected and in need of correction.

• Not done due to lack of prerequisites.

• Invalid due to method or data defects.

• Postponed with a specific reason and schedule.

Seasonal or wind conditions may not allow a full review of some functions. Simulation of wind input can verify the control logic, but does not prove the actual behavior of spray in wind.

The deferred test must have a person in charge, implementation conditions, deadline or implementation trigger, and acceptance criteria. The GSA guide also emphasizes the registration and tracking of quarterly and deferred tests. GSA Setup Guide ^[211]

30–14. Sample performance test report form

The form should allow a person who was not present during the test to understand the conditions and the result.

Sample registration of a security test

"By applying the approved test condition for the low level, an alarm was registered and the output of the display circuit went to the designated state. The actual behavior of the pump was observed and recorded. After fixing the situation, the reboot was done according to the approved logic. "Temporary settings have been removed."

Actual times and circuit IDs should be added to this report. The phrase "everything was right" is not enough for acceptance and future reference.

30–15. Training the user and proving the ability to work with the system

Training should be done with the set installed, the final settings and the actual role of the people.

The main topics are:

• Daily pre-start visit and control.

• Select the authorized program and normal start and stop.

• Detection of warnings and appropriate action.

• Monitoring water quality and recording the results.

• Limits of operator intervention and referral time to a specialist.

• Actions in case of power or communication failure.

• Use of documents and equipment identification.

• Maintaining backup copies and managing access.

To measure learning, the user must perform some specific tasks in the presence of the trainer; such as finding the cause of a test alarm, properly stopping a display or logging daily data.

Specialized training in electrical repairs, working with chemicals or changing control programs should be appropriate to the qualifications and responsibilities of individuals.

Figure 4–30 — On-site training

Suggested image: the operator performing a real task on the end system, along with the daily registration form; Login information and confidential details will not be displayed.

Subtitle: "Training can be evaluated when the user can perform the defined tasks."

30–16. Final delivery and base status registration

At the time of delivery, a specific version of the system state should be recorded so that future changes can be tracked.

This baseline includes the following:

• Plans and list of final equipment.

• Accepted settings of pumps, controllers and protections.

• Version of programs and shows.

• Pressure, flow, power and alignment reference values.

• Test records and bug fixes.

• Operation and maintenance instructions.

• Backup and recovery method.

• Spare parts, special tools and delivery items.

• Education records.

• Open cases and deferred examinations, if any.

In the introduction of GSO services, installation, commissioning, training and support are in the project service chain. In the delivery file of each project, the actual scope of these services, the contact person and the related obligations must be clearly recorded. GSO urban fountain services ^[212]

The minutes of the handover meeting should clarify when the responsibility for the operation, maintenance and protection of the collection will be transferred to the relevant party. The terms of the guarantee and handling of the remaining cases should also be included in the contract.

A sample of the proposed wording for the meeting minutes

"The scope of delivery includes the equipment and circuits listed in Appendix No. The results of the accepted tests are recorded in attachment number..., the version of documents and final settings in attachment number... and the remaining items with the person in charge and the hearing date are recorded in attachment number.... The permitted scope of exploitation and the responsibilities of the parties are determined according to these documents and the contract.

The first days of operation should be accompanied by regular data recording. This information makes it possible to compare daily performance with the accepted status at delivery.

Chapter 31 is dedicated to the operation and maintenance of urban fountains; Including daily, periodical and seasonal plans, spare parts management and failure follow-up method.

Operation and health