list of submittals typically expected from the contractor or system integrator for the automation portion of a WRRF:
• System integrator technical proposal;
• Automation system project schedule;
• Control system architecture;
• Instrument data sheets;
• Detailed panel drawings, including layout, wiring schematics, and so on;
• Automation equipment hardware;
• Instrument installation details;
• Software
• Alarm notification systems.
3.1.2 Change Orders
3.1.2.1 Change Order Management
A certain amount of change orders are inevitable for a project. Changes can be caused by user requests, design omissions, design errors, field conditions, or unforeseen situations. When such changes occur, design engineers should evaluate them, estimate their costs, and produce the documents needed to support them.
3.1.2.2 Common Risk Areas for Change Orders
It is important to agree on a scope of work with the contractor or system integrator before proceeding with processing of the change order. This will avoid misunderstandings between the contractor and engineer as to what is being provided. In addition, upgrade and expansion work on an operating facility is more time consuming than work on a new facility and requires a lot more coordination with the facility to ensure uninterrupted or minimal effect to operations.
3.1.3 Responding to Requests for Information and Request for Clarifications
Contractors and system integrators will often have questions for the design team during the construction phase. Such questions, or RFI, and their responses must be documented and filed with other design and project documents for future reference. Electronic documentation systems with appropriate security measures and access rights can make it easy to archive and retrieve this information.
3.1.4 Meetings with Contractors and Suppliers
The design team will meet with contractors and system suppliers often to clarify design issues that are not easily addressed in other forums. During the early phase of the contract, design engineers should schedule monthly meetings with the system integrator. Later meetings should include electrical contractors; heating, ventilation, and air-conditioning (HVAC) contractors; and other subcontractors for coordination purposes.
3.1.5 Site Visits
Although a construction management team (i.e., resident engineer, field inspectors, etc.) typically handles daily construction activities, the design team should visit the job site periodically to address and resolve implementation issues such as alternate installation procedures that could affect the design and overall project success.
3.1.6 Factory Acceptance Tests
Contracts for I&C systems typically specify that systems must be fully tested at the manufacturer’s facility before shipment. Depending on the size and type of control system, factory tests may involve simulation software (Blevins et al., 2000; Dougall, 1997).
The design engineer, end user personnel, or other designated parties typically witness this control system testing to ensure that the system is fully debugged, complies with design requirements, and is free of internal-wiring errors when the equipment leaves the factory. This reduces control system startup time and confines most of the remaining errors to field wiring or other field-related issues.
At least 2 months before testing begins, the contractor must submit a schedule of test dates and a factory test procedure to the engineer and owner. The factory test procedure must include all testing steps, checklists, and settings and a list of all test equipment to be used to verify that the scheduled testing will fulfill contract requirements.
When factory tests have been completed successfully, the contractor’s control system supplier should submit a report to the design engineer with the test results that clearly indicates that all deficiencies found during the factory test were corrected. Equipment should not be shipped until the contractor’s control system supplier receives a notice from the engineer that the test results were acceptable.
3.1.6.1 System Performance
Before the witnessed factory test, the instrumentation system supplier should perform a full-system test, during which the entire system must operate continuously for at least 100 hours without failure, in accordance with the requirements of the specifications and drawings. The purpose of this test is to ensure that any component failures are discovered before the witnessed factory test begins.
This test should verify that all the components work properly as an integrated system. It involves assembling the entire control system (i.e., hardware, software, peripheral devices, and interconnecting cables) on the factory test floor and using a workstation loaded with simulation software (simple control systems can typically be verified without simulation software) to operate the control system and simulate both treatment processes and signals from field devices that cannot be connected to the panel. If any component fails during this test, it should be replaced and the test restarted.
While the entire system is assembled, the supplier should inspect all panels, consoles, and cabinets to ensure that the following items and functions are correct and consistent:
• Nameplates and tags;
• Wire sizes and color coding;
• Terminal block contract ratings and number;
• Annunciator and terminal block spares;
• Proper wiring
