tunnel commissioning - · pdf filewest end of southbound tunnel experience in tunnel...
TRANSCRIPT
Richard Thorne P.E. CXA, Axiom Engineers
Tunnel Commissioning
21st National Conference on Building Commissioning
AIA Quality Assurance
The Building Commissioning Association is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request.
This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.
Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.
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Presentation Description
This presentation will cover project experience in applying basic commissioning principals and procedures to an uncommon commissioning environment – tunnel systems.
The presentation will cover:•Tunnel commissioning scope of work and growth•Experience with commissioning unique systems such as:
• Medium voltage electrical equipment• Radio communications• Complex Fire Protection (wet and dry)
•Scenario driven integrated test
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Presentation Description
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Yesterdays Tunnel Projects
Presentation Description
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Presentation Description
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At the end of this session, participants will be able to:
1. Apply basic commissioning processes to atypical systems2. Recognize project growth opportunities3. Understand importance of including manufacturers in commissioning
process4. Include operators and multiple organizations in integrated testing
Learning Objectives
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• Project Background• Commissioning Scope• Commissioned Systems• Commissioning Process• Integrated Test• Questions?
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West End of Southbound Tunnel
Experience in Tunnel CommissioningOutline
• Replace southbound access to and from Golden Gate bridge –Doyle Dr
• Original overpass no longer seismically safe
• Increase green scape –parkway not a freeway
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Project BackgroundProject Goals
Doyle Dr Transition
• Got the call• Tunnel or Electrical Commissioning
Experience?• Apply basic commissioning
principals to new systems• BSEE – Basic Understanding in
electrical systems• Attended 1 yr PG&E
Commissioning Course• Construction Site Experience• 20 years Naval experience
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Project BackgroundGetting Project
• Schedule of Commissioning Events• Integrate schedule with Construction
Schedule• Commissioning Plan
• Readiness, start-ups, functional tests, & acceptance criteria
• Training• Cx report contents• Schedule
• Provide checklists and test procedures
• Commissioning Checklist Log• Training – videotaping,
schedule and coordination with contractor
• Final systems integration test• Final report
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Commissioning ScopeFrom Specifications and Drawings
• Electrical• Medium Voltage
Switchgear• DC Battery Charger and
Power Supply• One for protective relays
and PLC controllers• One for emerg tunnel
lighting• Circuit Breakers• Uninterruptable Power
Supplies• 12-20KVA for traffic
operations and SCADA• 30KVA for tunnel lighting
• Protective Relays
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Commissioned Systems
• Electrical (cont)• Motor Control Centers• Lighting Systems (Tunnel,
street area at portals, and Substation)
• Grounding• Surge Arrestors• Transformers• Panelboards
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Commissioned SystemsCONT
• Mechanical• Substation fans• Hydrogen detection (added)• Carbon Monoxide System• Jet fans are future scope!
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Commissioned SystemsCONT
• Special Systems• Radio Rebroadcast• Call Boxes
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Commissioned SystemsCONT
• Special Systems• SCADA (Supervisory Control
And Data Acquisition)• Electrical Distribution• Lighting• Fire Protection (info only)• Carbon Monoxide Monitoring• Future Jet Fans• Substation HVAC• Call Boxes• Hydrogen Detection
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Commissioned SystemsCONT
• Commissioned Systems:• Fire Protection
• Deluge Tunnel System• Standpipe Tunnel System• Linear Heat Detectors• Fire Alarm Control Units• Fire Alarm Remote
Annunciators• Smoke Detectors• Manual Pull Boxes• Remote Fire Alarm and
control from central control station
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Commissioned SystemsCONT
• Drawing Review (growth opportunity)• Submittal Review• Commissioning Plan• Start-Up Plans (Prefunctional Checklists)
Development/Execution• Functional Tests Development/Execution• Training (growth opportunity)• Integrated Test Development/Execution• Report
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West End of Tunnel, digging to bottom level
Commissioning ProcessGeneral Process
• Many Parties Involved• CALTRANS (Numerous
Branches)• State Fire Marshall• Inspector of Record• Facilitator
• Understanding the project beyond the drawings themselves
• More emphasis on tracing power
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Commissioning ProcessDrawing Review Alternate power
supply not to be installed during
this phase
• Under-developed single line• Growth opportunity
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Commissioning ProcessDrawing Review
200 sheets of drawingsto filter what is on each panels, if anything
• Lessons Learned:• Updating process did not show clouds or revision marks.
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Commissioning ProcessDrawing Review
• Lessons Learned:• Updating process did not show clouds or
revision marks. • Understanding Ladder Logic and
controls
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Commissioning ProcessDrawing Review
• Standard process and comments for HVAC type systems
Equipment capabilities match design?Is equipment going to fit?Access?
• Difference from HVAC system – more capability issues between equipment contacts and SCADA inputs.
• Education on how protective relay logic works
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Commissioning ProcessSubmittal Review
• Lessons Learned:• Panel board number and type
of circuit breakers not matching design
• Lighting controller O&M sequence backwards
• Finding terminal blocks on submittal drawings that were not installed
• Points not terminated at controller
• Learn from manufacturer
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Commissioning ProcessSubmittal Review
• Lessons Learned:• Learn from manufacturer
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Commissioning ProcessSubmittal Review
• Standard process and comments for HVAC type systems
• Installed equipment does not match submittal
• Missing items from design• Maintenance Access
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Commissioning ProcessInstallation Verification
• Lessons Learned:• Circuit breakers not matching
design• CO monitor cover could not
open• Missing insulation on
condensate drain
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Commissioning ProcessInstallation Verification
On East Side of Tunnel looking West – 1 month to opening
• Additional sections normally not found in HVAC type projects
• System Testing Details• Specific system start-up plan
responsibilities• Specific functional test plan
responsibilities• Phased commissioning sequence
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Commissioning ProcessCommissioning Plan
Deluge Control Valve in Niche
• Direct application of building commissioning• Proceed from components to systems• Composed of specification checks• Refer to items in the installation manual
• Review start-up plans provided by installers/manufactures.
• Radio rebroadcast• Fire protection system (alarms)• SCADA
• Basic common checks• Connected correctly?• Initial settings (Protective Relay)
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Commissioning ProcessStart-up Plans
Medium Voltage Circuit Breaker
• Lessons Learned• Big difference with HVAC – most of
team was NOT familiar with commissioning process
• What start-ups really need to happen• Risk of not completing:
• Safety – lack of eyewash stations• Makes functional testing go MUCH
slower• Need to use unfamiliar publications on
unfamiliar projects
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Commissioning ProcessStart-up Plans
Medium Voltage Circuit Breaker
US Army Commissioning of Electrical Systems for Command, Control, Communications, Computer, Intelligence, Surveillance, and Reconnaissance Facilities Technical Manual is a great resource for commissioning power distribution systems
• Direct application of building commissioning• Start from component and work up to
systems and then integration• Need to confirm component functions
based on controlling inputs• Major difference than HVAC – not all
components need functional tests• Electrical equipment (transformer, panel
boards)
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Commissioning ProcessFunctional Tests
• Lessons Learned:• Found issues that could have been caught
earlier• Contacts not present to provide
feedback to SCADA• Lack of pre-recorded messages• Further slows functional test process
• Still catches issues that everyone misses – spray blockage
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Commissioning ProcessFunctional Tests
• Similar to building commissioning except:• Training had to cover all three
maintenance shifts• Training plans reviewed by State Fire
Marshall• State Fire Marshall witness some
training• Great opportunity to increase scope
• Who else has a grasp on all of the systems and how the training should be organized?
• Developed detailed class schedule
• Collected and submitted training plans
• Even provided some training (expert in radio rebroadcast system????)
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Commissioning ProcessTraining
• Integrated Test:• Goal is to show how tunnel systems
work together in a major tunnel incident
• Demonstration for State Fire Marshall for ALL systems
• Electrical• Fire Protection• Mechanical• Operators• Special Systems
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Commissioning ProcessIntegrated Test
Completion of Integrated Test
• Scenario driven (plan)• Start with simulated car
wreck• Driver uses call box to report
accident• Smoke bomb lit off to
simulate smoke to cameras• Activation of LHD (triggered
at FACU)• Operators respond
• Plan was just a plan, a guide
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Commissioning ProcessIntegrated Test
Completion of Integrated Test
• What really happened• Continued testing and
troubleshooting of the fire alarm system.
• Conducted functional tested on systems not ready before this point
• Battery Charger, street lighting, CO system
• Actual scenario testing happened on Friday after heat testing on Thur
• Lessons Learned:• Be Flexible!!!!
• Correct deluge reaction• LHD detects heat• Operator has 30sec to
acknowledge• Once acknowledged, 90sec delay• End of 90sec, water will release
• What actually happened during scenario
• Call box activation successful• LHD zone (6) that was switched ON
different than location of smoke bomb (8)
• Operators shut down tunnel, acknowledged LHD zone 6
• Vendor entered control center and manually activated zone 7 and 8
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Commissioning ProcessIntegrated Test
• The primary focus during integrated testing –open the tunnel
• Numerous tests had to be done latter• Substation external lighting/SCADA• Security system (door sensors)• Substation fan operation with regards to
high hydrogen• Tunnel lighting• Troubleshooting
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Commissioning ProcessFollow On Testing
West Bore, After Tunnel Opening
• Similar to building commissioning report, except:
• Specifications description of report is more like systems manual
• Major component of systems manual –Narratives!
• Include ALL factory tests, start-up reports, functional tests, and training documentation
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Commissioning ProcessFinal Report
• Try to always say YES to opportunities• Look for growth opportunities and ways to help
project• Apply standard commissioning processes to
new systems with base knowledge• Include all parties and manufactures in
process
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Summary
Tunnel Of Today
Tunnel Of Yesterday
THANK YOU
Richard Thorne, P.E., [email protected]