20240909IPC to Staff 94(e) - Attachment 6 - HCPR190001 BOP Commissioning HCPR_AUTOSPILL_GATE_1_COMMISSIONOING.pdf

SPILLGATE 1 COMMISSIONING
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
EMS CHECKOUT
1. VERIFY SPILLGATE ALARMS
2. VERIFY SETPOINT CONTROL FOR RAISING
3. VERIFY SETPOINT CONTROL FOR LOWERING
DEREK VANDERMEER CSS 5/27/2024