Approval

Project manager

0 Oct. 2018 Bucataru Ghe. Pasare Ghe. Manea Simion

NO. DOCUMENT
REV. DATE DESIGNED CHECKED APPROVED
DESCRIPTION
Revision Sheet
CUSTOMER:
MINISTRY OF ELECTRICITY (MOE)
REPUBLIC OF IRAQ
PROJECT :
IFB no. M21-21-2016
Rehabilitation of Unit 3
Facilities and Common System, Al Mussaib Thermal Power Plant Rehabilitation

CONTRACTOR:

BLACK SEA POWER GENERATING FZCO

DESIGNED BY DATE

Bucataru Ghe. October 2018

CHECKED BY DATE
TITLE:
Pasare Ghe. October 2018
Reliability Run Test Procedure
APPROVED BY DATE

Manea Simion October 2018

Contract No. DOCUMENT NUMBER REV.NO.

IFB no. M-21-
2016 350-BSP- 0155 0

This document is restricted. Neither he whole nor any part of this document may be disclosed to any third party without the
prior written consent of BLACK SEA POWER GENERATING FZCO, in which the copyright of this document is vested. All
copyrights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or
transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior
consent of the copyright owner

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 Contents
1 PURPOSE .......................................................................................................................... 3
2 DEFINITIONS ..................................................................... Error! Bookmark not defined.
3 TEST TOOLS...................................................................................................................... 3
4 PRE-CHECK ITEMS ........................................................... Error! Bookmark not defined.
5 TEST PROCEDURE ........................................................................................................... 5

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1. PURPOSE
1.1. The purpose of Reliability Run (RR) is to demonstrate and prove the
continuous reliable operation.

1.2. The purpose of this document is to establish guidelines for performing

the RR during the course of work at "Waste Water Plant"
(Commissioning phase).
1.3. This document is applicable for RR also for each Facilities and
Common System Units (WWT, WT, N2) of the Al Mussaib Thermal
Power Plant Rehabilitation Project together with associated
ancillary plant. The RR trial should be in accordance with the Contract
between BSP and MOE.
1.4. This very document refers as an exemplification when applying RR
procedure for WWT Plant for the purpose of demonstration and
confirmation of the reliability of the Waste Water Treatment plant

2. RR TEST TOOLS

2.1 During RR test period no additional measuring instruments are compulsory

needed for measuring and recording the values of functional parameters
from the Plant – there should be used the existing measuring
instruments already installed on plant within the Plant Automation
System (local and automation panels instruments)

2.2 The reliability run test will reveal the actual values reached by the plant
parameters in continuous operation under normal conditions by means
of instrumentation from the automation and control system with which
the technological plant is actually equipped. Mainly the performance
values will be measured recorded, processed from value indicated at
dedicated instruments already installed in the System (e.g pH Meter,
online analizers etc.);

3. PRE-CHECK ITEMS

The following items should be completed before system reliability run test:

A. Any mechanical / errection / installing work is finished on all

equipment within;

B. Functional and preliminary tests

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 C. Trial run

D. Initial operation

Note: The (Reliability run) RR test is a step within the commissioning

activities, following the steps specified above and followed by this step:

E. Performance and acceptance tests.

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4. RELIABILITY RUN (RR) TEST PROCEDURE

4.1 RR will commence after the BSPG has notified MOE of readiness to
commence the test and it shall be agreed by MOE.

4.2 Plant will be operated by WWT station operation staff under the direct
supervision of BSPG.
4.3 Unit will be required to operate under the working conditions of the plant
according to operating procedures and within the limits of output
specified, without failure or interruption resulting from faults of
equipment, for a period of fifteen days, during which time such unit will
be operated continuously at Full capacity (depending of waste water
flow needed to be treated) providing proper parameters for treated
water delivered onto the river as per contract specification. If due to
unavailability of design chemicals substances needed to be used in
treatment of waste water during period of RR test, the unit treating
capacity will be adjusted accordingly based on maximum allowable
total flow and in this case it will not necessitate of repetition of test
hours.

4.4 Interruption of RR caused by faults on equipments supplied under the

contract will necessitate repetition of the RR if such interruption is more
than 12 hours between opening and closing the flow of ww inlet and
cleaned water outlet of the Plant and if more than 24 hours in aggregate

4.5 Major Incidents such as Unit trip or shutdown.

4.5.1 The failure of any operator or operators to respond to an
operational requirement which result in a unit trip will not be considered
a failure or interruption. In such case, the unit shall be restarted and the
RR runtime will continue to accumulate when the unit reaches the status
at which the trip occurred
4.5.2 If it is necessary to stop the unit due to external factors such as
transmission system trouble, shortage of reactiv chemicals for treatment,
etc., the unit may be shutdown for any necessary adjustments or
alterations to be made by Operating personel, the RR shall be
considered to have been suspended for the period of the shutdown.
During such period, BSPG – Commissioning Team members may also
make plant adjustments and modifications

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 4.5.3 If it is necessary to shutdown the unit due to natural calamity
or for the safety of personnel, plant or equipment, the RR shall be
considered to have been suspended for the period shutdown.
4.5.4 If unit is tripped or shutdown due to or arising from defects in
design, material or workmanship (but not otherwise) sufficient to
prevent the agreed usage of the Unit, the RR trial period for the unit or
part shall recommence after the contractor has remidied the cause

- Minor incident, such as instruments faults, or equipment faults

requiring the operation of stanby plant, or such other minor failure or
interruption as may be agreed between the parties shall not constitute a
failure or interruption of the Reliabilty Run. (Minor incidents may be as follows:
Equipment faults requiring the operation of stanby plant/ Instrumentation monitoring system
errors/ Instrumentation control system defects/ Minor Mechanical oil leakage, water leakage,
air leakage, efluent leakage, etc)
4.5.5 Report will be prepared by the concerned party to identify the
cause of any incident during RR test.

4.5.7 BSPG may carry out minor adjustments to plant equipment if

necessary, during the RR, provided that such adjustment do not in any
way interfere with or prevent commercial use of the plant.

4.5.8 During the period of RR there should be no testing or other work

activities, which can disrupt the testing process of RR

5. MONITORING AND REPORTING

5.1 BSPG shall submit a daily operation record, i.e. 24 hours trend
graph indicating parameters of clearness of the water outlet from the
plant during RR period which proves that unit was operated 24 hours
continuously
5.2 All events during the period of RR data is recorded on the attached
form (Annex 4)

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 6. ACCEPTANCE CRITERIA OF RELIABILITY RUN
6.1 The 15 Days (360 hours) running of the plant in accordance with the
Test Procedure is considered as successful completion of RR

6.2 During the period of RR interruption (no cleaned water delivered onto
the river) or trip in one main equipment for storrage / discharge of subproducts
resulting from cleaning waste water process is not more than 3 hours

6.3 In the RR period (360 hours), number of hours of shutdown until the
recovery plant, cumulatively not more than 12 hours

6.4 At the end of RR test, if all the works have been done and closed
successfully, a concluding Certificate shall be issued (by RR comitee)
according Annex 2

6.5 A reliability run records shall be filled in as per Annex. 4

7. RR committee
7.1 In any case is this procedure which will require critical decisions, shall
be discussed and agreed by the RR committee. The RR committee shall be
consist of representatives of the MOE, TEPSCO, BSPG
7.2 The reliability run test should be proposed to begin according to the
discussion and agreement between concerned parties in a RR committee
meeting (using the agreement template from Annex 1)

7.3 The reliability run test for waste water treatment plant will be carried out
mainly with automation operation and occasionally manual / local comand
operation in continuous run under real conditions for 15 days and checks on
every 4 hours.

7.4 In case the malfunction or fault break out under auto operation during
reliability run test, the reliability run test will be restarted after necessary action
to be taken to restore running / operationing good condition.

7.5 The verified parameters such like flow rate, pressure, temperature,
chemical and phisical measured through online analysers and etc. will be
written down / recorded on the attached check sheet (template) (Annex 3).

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Annex 1

Reliability Run Test starting Agreement

This is to certify that on date:………………………. at hour:………………………

the Reliability Run Test for ……………………………………………………..
………………………(WWTP, WTP, N2P)…………………………………..Plant
from Al Mussaib Thermal Power Plant Rehabilitation Project is agreed by all
parties to be started.

No Name Organization Position Signature

Annex 2

Reliability Run Test starting Agreement

This is to certify that on date:………………………. at hour:………………………

the Reliability Run Test for ……………………………………………………..
………………………(WWTP, WTP, N2P)…………………………………..Plant
from Al Mussaib Thermal Power Plant Rehabilitation Project has
successfully completed according to the RR test procedure.

No Name Organization Position Signature

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 Annex 3

DAYLY CHECK SHEET within RR

PROJECT DATA OF ISSUE 1 OF 1

NAME
WASTEWATER TREATMENT PLANT CHECKED BY

ITEM NAME

ITEM No.

DAY NUMBER: ____ /

JUDGEMNT
AVERAGE
NO. CHECKITEM GUARANTEE UNIT 4hr 8hr 12hr 16hr 20hr 24hr REMARK

1 FLOW 70 m3/hr

2 pH 7~9

Oil &
3 〈10 mg/L
Grease

4 TSS(Average) 〈30 mg/L

5 TSS(Max.) 〈50 mg/L

Settleable
6 Nil mg/L
Solids

7 Cloride 〈50 mg/L

* NOTE
Operator should be measure flow & pH value of treated water discharged every 4hrs. Others item measure after
24hr.

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 Annex 4 - RELIABILITY RUN RECORDS

RELIABILITY RUN RECORDS

DATA OF ISSUE CHECKED BY
PROJECT NAME
WASTEWATER TREATMENT PLANT
ITEM No.
ITEM NAME

No DATE HOURS TYPE OF Actual running TIME OF EVENT INDICATION RECTIFICATION REMARK
DISTURBANCE state of the plant
WWT
MAX MIN START FINISH

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