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Home My WebLink About20240909IPC to Staff 94(e) - Attachment 6 - HCPR190001 BOP Commissioning HCPR_AUTOSPILL_COMMISSIONOING.pdf SPILLGATE TESTING 1. 1\0 CHECKOUT 480V OFF 2. SPILLGATE #1 IN OFF POSITION 3. REMOVE LOTO 4. POWER 480VAC 5. PUT SPILLGATE #1 IN MANUAL 6. UNPLUG DRUM ENCODER, VERIFY ALARM AND NO MOVEMENT 7. UNWIRE GATE ENCODER, VERIFY ALARM AND NO MOVEMENT 8. RAISE SPILLGATE WITH MANUAL CONTROL 9. VERIFY ENCODER ROTATION 10.STOP SPILLGATE RAISE 11.LOWER SPILLGATE WITH MANUAL CONTROL 12.STOP SPILLGATE WHEN CORRECT SLACK IS ACHIEVED 13.ZERO DRUM ENCODER, THIS IS OUR STOP. 14.VERIFY GATE IS UNAVAILIBLE AFTER LOWERING IN MANUAL 15.RAISE SPILLGATE WITH MANUAL CONTROL TO 1 FOOT 16.SWITCH CONTROL TO AUTO 17.LOWER SPILLGATE WITH AUTO CONTROL TO CLOSED 18.VERIFY GATE ENCODER OF 0 POSITION 19.VERIFY DRUM ENCODER OF 0 POSITION 20.VERIFY ENCODERS STOP SPILLGATE NOT LOWER LIMIT 21.VERIFY PROPER SLACK 22.RAISE SPILLGATE WITH SETPOINT 23.UNPLUG DRUM ENCODER, VERIFY ALARM AND SWITCH TO OTHER ENCODER, PLUG ENCODER BACK IN. 24.UNWIRE GATE ENCODER, VERIFY ALARM AND SWITCH TO OTHER ENCODER 25.UNPLUG DRUM ENCODER, VERIFY GATE BECOMES UNAVAILABLE WITH BOTH ENCODERS FAIL 26.PLUG DRUM ENCODER IN 27.REWIRE GATE ENCODER 28.LOWER WITH SETPOINT 29.CHANGE FAIL TO MOVE TIMER TO 5 SECONDS, OPEN SPILLGATE WITH SETPOINT AND VERIFY FAIL TO MOVE ALARM. CHANGE FAIL TO MOVE TIMER BACK TO ORIGINAL TIME. 30.VERIFY LOOKUP TABLE IS CORRECT FROM LAST SPILLGATE TEST AUTOSPILL TESTING 1. WIRE TESTING RELAY'S FOR 2 UNITS 2. WIRE PROCESS CALIBRATOR FOR 2 UNITS 3. VERIFY CORRECT CONTACTS ARE USED 4. TEST 1 SETUP —VERIFY SIREN WORKS CORRECTLY a. MS RELAY HIGH b. 94G RELAY LOW c. UNIT TRIP RELAY LOW d. UNIT FLOW AT 12 mA, 5077 CFS 5. TEST 1-UNIT TRIP a. UNIT TRIP RELAY FROM LOW TO HIGH b. 94G RELAY LOW c. MS RELAY FROM HIGH TO LOW d. VERIFY CFS MOVES TO 5077 e. VERIFY GATE OPENS TO CORRECT SETPOINT— 3 FT 6. TEST 2 SETUP a. MS RELAY HIGH b. 94G RELAY LOW c. UNIT TRIP RELAY LOW d. UNIT FLOW AT 12mA, 5077 CFS 7. TEST 2- 94G — UNWIRE SSI ENCODER a. MS RELAY HIGH b. 94G RELAY FROM LOW TO HIGH c. UNIT TRIP RELAY LOW d. VERIFY CFS MOVES MINUS SNL— 3676 — 1.8 FT e. VERIFY GATE SETPOINT - 3676 f. UNIT TRIP RELAY MOVE LOW TO HIGH g. VERIFY CFS SNL h. VERIFY GATE SETPOINT OPENING — 3 FT i. REWIRE SSI ENCODER 8. TEST 3 SETUP — UNPLUG DRUM ENCODER a. MS RELAY HIGH b. 94G RELAY LOW c. UNIT TRIP RELAY LOW d. UNIT FLOW AT 12mA, 5077 CFS 9. TEST 3 — 94G a. MS RELAY HIGH b. 94G RELAY MOVE LOW TO HIGH c. UNIT TRIP RELAY LOW d. VERIFY CFS MOVES MINUS SNL - 3680 e. DO NOT LET GATE GET TO SETPOINT f. UNIT TRIP RELAY MOVE FROM LOW TO HIGH g. MS RELAY MOVE FROM HIGH TO LOW h. VERIFY CFS MOVES SNL - 5080 i. VERIFY GATE SETPOINT OPENING — 3 FT j. PLUG DRUM ENCODER BACK IN 10.TEST 4 SETUP a. MS RELAY HIGH b. 94G RELAY LOW c. UNIT TRIP RELAY LOW d. UNIT CFS 6.2 mA, 1400 CFS 11.TEST 4 — STARTUP TRIP a. MS RELAY HIGH b. 94G RELAY LOW c. UNIT TRIP RELAY MOVE FROM LOW TO HIGH d. MS RELAY MOVE FORM HIGH TO LOW e. VERIFY CFS MOVE — 1400 CFS f. VERIFY GATE OPENING - .82 FT 12.TEST 5 SETUP — 2 UNIT TRIP a. U1 MS RELAY HIGH b. U1 94G RELAY LOW c. U1 UNIT TRIP RELAY LOW d. U1 CFS 16 mA, 7612 e. U2 MS RELAY HIGH f. U2 94G RELAY LOW g. U2 UNIT TRIP RELAY LOW h. U2 CFS 16 mA, 7612 13.Test 5 a. U1 UNIT TRIP RELAY FROM LOW TO HIGH b. U1 MS RELAY FROM HIGH TO LOW c. VERIFY CFS MOVE — 7612 CFS d. VERIFY GATE SETPOINT— 5 FT e. U2 94G RELAY FROM LOW TO HIGH f. VERIFY CFS MINUS SNL MOVE — 5200 CFS g. VERIFY GATE OPENING — 3.3 + 5 FT = 8.3 FT 14.TEST 6 SETUP — 2 GATES AVAILIBLE, 1 GATE FAIL TO MOVE a. MAKE PLC THINK GATE 2 IS AVAILIBLE b. MS RELAY HIGH c. 94G RELAY LOW d. UNIT TRIP RELAY LOW e. UNIT CFS 16 mA, 7500 CFS 15.TEST 6 a. UNIT TRIP RELAY FROM LOW TO HIGH b. MS RELAY FROM HIGH TO LOW c. VERIFY CFS MOVE — SHOULD SPLIT 2.3 ON EACH d. VERIFY GATE FAIL TO MOVE e. VERIFY SETPOINT GETS MOVED TO AVAILIBLE GATE —4.6 FT 16.TEST 7 SETUP — 3 GATES AVAILIBLE, 2 GATE FAIL TO MOVE a. U1 MS RELAY HIGH b. U1 94G RELAY LOW c. U1 UNIT TRIP RELAY LOW d. U1 CFS 16 mA, 7500 CFS 17.TEST 7 a. FAIL TO MOVE TIMER GATE 2 — 20S, GATE 3 — 40S b. UNIT TRIP RELAY FROM LOW TO HIGH c. MS RELAY FROM HIGH TO LOW d. VERIFY CFS MOVE — SHOULD SPLIT 7500 CFS e. VERIFY GATE OPEN — 1.5 FT PER GATE f. VERIFY GATE FAIL TO MOVE — GATE 2 g. VERIFY GATE FAIL TO MOVE — GATE 3 h. VERIFY SETPOINT GETS MOVED TO AVAILIBLE GATE — 5 FT EMERGENCY AUTOSPILL PLC INPUTS 1. PULL RELAY'S FROM BOP PLC DROP 1 TO OLD AUTOSPILL PLC 2. USE A SEPARATE ANALOG INPUT ON DROP 9 FOR HH HEADWATER 3. REMOVE HH HEADWATER POINT AND INSERT NEW TEST POINT FROM ANALOG INPUT 4. MOVE PROCESS CALIBRATOR TO SIMULATE HH HEADWATER ANALOG POINT 5. VERIFY SPILLGATE MOVES TO 3.3 FT, 5600 CFS 6. MOVE PROCESS CALIBRATOR TO SIMULATE AN EXTREME HIGH HEADWATER ANALOG POINT 7. VERIFY SPILLGATE MOVES AN ADDITIONAL— 2 FT, 3000 CFS 8. TOTAL 5.2 FT, 8500 CFS 9. TEST 8 SETUP — UNIT TRIP WITH HH HEADWATER a. MS RELAY HIGH b. 94G RELAY LOW c. UNIT TRIP RELAY LOW d. UNIT CFS 12mA, 5075 CFS 10.TEST 8 a. UNIT TRIP RELAY FROM LOW TO HIGH b. MS RELAY FROM HIGH TO LOW c. VERIFY CFS MOVE — 5075 + 8500 CFS = 13594 CFS d. VERIFY GATE MOVE — 8.2 FT 11.MOVE PROCESS CALIBRATOR TO PROPER HEADWATER LEVEL 12.MOVE GATE TO 0 POSITION 13.SWITCH ANALOG POINTS FROM HEADWATER TO TAILWATER 14.MOVE PROCESS CALIBRATOR TO SIMULATE LL TAILWATER ANALOG POINT 15.VERIFY SPILLGATE MOVES TO 3.3 FT, 5600 CFS 16.TEST 9 SETUP — UNIT TRIP WITH LL TAILWATER a. MS RELAY HIGH b. 94G RELAY LOW c. UNIT TRIP RELAY LOW d. UNIT CFS 12 mA, 5075 CFS 17.TEST 9 a. UNIT TRIP RELAY FROM LOW TO HIGH b. MS RELAY FROM HIGH TO LOW c. VERIFY CFS MOVE — 5075 + 5600 = 10675 CFS d. VERIFY GATE MOVE — 3.5 + 3.5 = 7 FT 18.MOVE PROCESS CALIBRATOR TO SIMULATE NORMAL TAILWATER 19.TURN LL TAILWATER BYPASS SWITCH TO BYPASS LL TAILWATER 20.MOVE PROCESS CALIBRATOR TO SIMULATE LL TAILWATER ANALOG POINT 21.VERIFY SWITCH DISABLES LL TAILWATER PLC SPILL 22.MOVE PROCESS CAIBRATOR TO SIMULATE NORMAL TAILWATER LEVEL 23.REMOVE TEST EQUIPMENT 241EAVE AUTOSPILL RELAY'S ON BOP DROP 1 DISABLED EMERGENCY AUTOSPILL HARD WIRED RELAY'S 1. 1/0 CHECKOUT FOR EMERGENCY AUTOSPILL HARD WIRED RELAY'S 2. MEASURE RESISTANCE ON THE EMERGENCY AUTOSPILL CIRCUIT 3. CLOSE BREAKER 4. SET GATE RAISE TIMER TO 2 MINUTES 5. SET DRIVE TIMER TO 2 MINUTES —VERIFY TIMER MODE AND TIME 6. SET SIREN TIMER FOR 1 MINUTE 7. JUMP HH HEADWATER SWITCH 8. VERIFY GATE RAISES FOR 2 MINUTES 9. VERIFY DRIVE TIMER TIMES FOR 2 MINUTES 10.VERIFY GATE RAISES FOR ANOTHER 2 MINUTES 11.REMOVE JUMPER 12.PLACE SPILLGATE 1 IN AUTO AND LOWER GATE TO 0 POSITION 13.PLACE SPILLGATE 1 IN OFF TO SIMULATE A PLC FAILURE 14.PLACE JUMPER ON LL TAILWATER SWITCH 15.VERIFY SIREN TIMES FOR 1 MINUTE 16.VERIFY GATE RAISES FOR 2 MINUTES 17.VERIFY DRIVE TIMER TIMES FOR 2 MINUTES 18.VERIFY GATE RAISES FOR ANOTHER 2 MINUTES 19.REMOVE JUMPER 20.VERIFY TIMER LOGIC STOPS TIMING 21.PLACE EMERGENCY SPILL DISABLE SWITCH TO DISABLE 22.INSTALL JUMPER ON LL TAILWATER SWITCH 23.VERIFY LL TAILWATER EMERGENCY SPILL DOES NOT OPERATE 24.REMOVE JUMPER 25.RESTORE EMERGENCY SPILL SWITCH TO NORMAL 26.PLACE SPILLGATE 1 IN AUTO AND LOWER GATE TO 0 POSITION 27.CHANGE DRIVE TIMER TO 45 MINUTES 28.VERIFY GATE TIMER IS AT 2 MINUTES 29.VERIFY SIREN TIMER IS AT 1 MINUTE 30.PLACE SPILLGATE SELECTOR SWITCH TO SPILLGATE 2 31.JUMP LL TAILWATER TO VERIFY SPILLGATE 2 RELAY ENERGIZES AND DOES NOT MOVE SPILLGATE 1 32.PLACE SPILLGATE SELECTOR SWITCH TO SPILLGATE 3 33.JUMP LL TAILWATER TO VERIFY SPILLGATE 3 RELAY ENERGIZES AND DOES NOT MOVE SPILLGATE 1 34.PLACE SPILLGATE SELECTOR SWITCH TO SPILLGATE 1