H.E.R.P.S — Installation, Commissioning & Operation Guide

Revision D Installation & Commissioning Framework

The H.E.R.P.S Revision D R2.0 installation and commissioning architecture is organized as a controlled engineering sequence rather than a collection of independent installation tasks.

The physical build progresses from structural skid preparation through pump assembly, drive-system installation, hydraulic routing, recovery-train integration, thermal equipment, electrical cabinets, BESS, instrumentation, cabling, pressure testing, flushing, final alignment and pre-FAT completion. The sequence is specifically arranged to reduce interface clashes, inaccessible connections, nozzle strain, contamination and late-stage alignment loss. :contentReference[oaicite:0]{index=0}

Machine Installation Baseline

These package-level values form the coordinated Revision D installation basis, while validation-controlled, OEM-controlled and site-controlled details remain subject to their respective release gates. :contentReference[oaicite:1]{index=1}

Controlled Real-World Installation Sequence

Revision D divides the physical realization of the H.E.R.P.S package into coordinated build and installation phases.

1. Engineering Release & Incoming Inspection — confirm released documentation, traceable materials, approved purchased equipment and controlled interfaces.
2. Structural Skid Preparation — fabricate and inspect the structural base, equipment-support areas, mounting interfaces and lifting provisions.
3. Pump Component Manufacturing & Inspection — manufacture and inspect pressure parts and rotating components under the applicable engineering and quality controls.
4. Pump Rotor & Casing Assembly — assemble the primary rotating and hydraulic machine while maintaining cleanliness, controlled fits, free rotation and inspection records.
5. Pump & Motor Installation — mount the pump and SynRM drive and establish preliminary mechanical alignment.
6. Main Hydraulic Piping — install suction, common discharge and direct hydraulic process paths using independently supported piping.
7. Recovery Train Installation — install the hydraulic energy-recovery turbine, PMG and associated controlled recovery branch.
8. Thermal Management Installation — install cooling equipment, thermal rack components and the associated closed-loop cooling circuit.
9. Electrical & Energy Storage Integration — install electrical cabinets, power conversion, DC equipment, BESS, supercapacitor systems and cable-routing infrastructure.
10. Instrumentation & Field Wiring — install, terminate, identify and test field instrumentation, I/O and associated control wiring.
11. Pressure Testing & Flushing — verify pressure integrity, cleanliness and restoration of the hydraulic and cooling systems.
12. Final Piping-Connected Alignment — verify shaft alignment, soft foot, piping strain and final machine condition after all permanent connections are complete.
13. Pre-FAT Release — close or formally control outstanding punch-list items before factory acceptance testing begins.

This phase structure is defined directly in the Revision D real-world build sequence. :contentReference[oaicite:2]{index=2}

Mechanical Alignment & Installation Integrity

Alignment is controlled throughout the installation process rather than treated as a single final activity.

The pump and motor are initially mounted and aligned before permanent process piping is fully connected. Final alignment is then checked again after the hydraulic system is installed so that pipe strain, mounting distortion or support loads cannot silently alter shaft alignment.

The Revision D pre-FAT checklist requires accepted preliminary and final pump/motor alignment records, identification of the hot-growth basis, correction of soft foot, independently supported DN350 suction and DN300 discharge/direct/recovery piping, acceptable nozzle strain and proven equipment-removal corridors. :contentReference[oaicite:3]{index=3}

Pre-FAT Readiness

Factory testing does not begin simply because the package has been physically assembled. Revision D requires a formal pre-FAT readiness condition.

• Revision-controlled machine interfaces verified
• Vendor-certified equipment envelopes incorporated
• No unresolved physical clashes affecting release
• Pump and motor alignment records accepted
• Main hydraulic piping independently supported
• Pressure boundaries tested as required
• Hydraulic and cooling systems flushed and restored clean
• Power and control/instrument segregation verified
• Bonding, continuity and insulation checks completed
• Instrumentation calibrated and correctly tagged
• Trips, E-stops, permissives and fail states verified
• BESS and supercapacitor commissioning limited to approved procedures
• Open punch-list items formally categorized

Factory Acceptance Testing — FAT

FAT verifies the assembled H.E.R.P.S package at the factory or approved test facility before shipment.

Acceptance is evidence-based: a design target, calculated result or CAD value does not become an accepted machine result until it is verified by the applicable test or inspection procedure. Test instruments are required to have appropriate traceable calibration, and deviations or temporary test configurations must be identified and dispositioned. :contentReference[oaicite:4]{index=4}

Principal FAT Activities

1. Document and configuration verification
2. Dimensional and as-built survey
3. Mechanical inspection and free-rotation checks
4. Hydrostatic and leak testing
5. Electrical continuity, insulation and bonding checks
6. Control I/O, permissive, trip and interlock simulation
7. Cooling-loop functional testing
8. No-load / low-load rotation and controlled speed testing
9. Pump hydraulic performance verification
10. Recovery turbine / PMG / rectifier testing
11. BESS / DC conversion / supercapacitor / DC-link testing
12. Integrated thermal and load testing
13. Final protective-trip and controlled-shutdown testing
14. Post-test inspection and NCR closure
15. Signed FAT release when required records are complete

The Revision D FAT program explicitly covers hydraulic, rotating, electrical, thermal, energy-storage, recovery and safety functions as one integrated package. :contentReference[oaicite:5]{index=5}

Site Installation & SAT Preconditions

Passing FAT does not by itself establish site readiness. Site Acceptance Testing verifies the installed package together with the actual site interfaces.

• Approved site foundation, anchors and grout complete
• Foundation levels and anchor coordinates surveyed
• Electrical and process utilities available
• Actual protection settings installed and verified
• Plant suction conditions and downstream pressure profile confirmed
• Skid anchored and grouted
• Permanent piping independently supported
• No unacceptable nozzle strain
• Final piping-connected alignment completed
• BESS site safety interfaces approved
• LOTO, guarding, E-stops and safe access complete
• Approved commissioning plan and abort criteria issued

These are explicit SAT prerequisites in the Revision D acceptance program. :contentReference[oaicite:6]{index=6}

Commissioning Philosophy

Commissioning progresses from safe static verification into controlled dynamic operation. Systems are proven incrementally rather than placing the complete machine immediately into full-load operation.

Mechanical, hydraulic, electrical, thermal, instrumentation, control and protection functions must each demonstrate readiness before the machine is advanced to higher-energy operating states.

FAT establishes the factory package condition, while SAT and commissioning confirm actual installation interfaces and operating behaviour. Neither replaces the other where site-dependent conditions govern machine performance or safety. :contentReference[oaicite:7]{index=7}

Normal Grid-Fed Startup Sequence

The Revision D operating architecture requires startup permissives to be healthy before motor torque is enabled.

1. Confirm operating mode and authorized operator control.
2. Verify that maintenance lockouts and equipment-isolation conditions permit startup.
3. Verify emergency-stop loops, independent protective trips and critical sensor health.
4. Start and prove required thermal-management operation.
5. Verify suction-path availability and establish the direct discharge path.
6. Confirm switchgear and AFE/VFD readiness, including the approved precharge sequence.
7. Keep hydraulic energy recovery disabled or bypassed during initial acceleration unless a validated automatic startup sequence specifically permits otherwise.
8. Accelerate the SynRM-driven pump through the validated speed ramp.
9. Establish stable process flow and pressure.
10. Transition to the selected automatic flow-control or pressure-control mode.
11. Enable energy recovery only after hydraulic conditions, direct-path fallback capability and PMG/DC-link readiness are proven.
12. Enable BESS support functions only when BMS and associated conversion systems report valid readiness.

The Revision D system specifically requires the direct hydraulic process path to be available and treats energy recovery as a secondary function, not a prerequisite for normal pump startup. :contentReference[oaicite:8]{index=8}

H.E.R.P.S Operating Modes

These modes and their safety constraints are defined by the Revision D functional-safety architecture. :contentReference[oaicite:9]{index=9}

PLC, HMI, SCADA & Operator Interface

The H.E.R.P.S control architecture integrates the PLC, local HMI, SCADA interfaces, instrumentation and field I/O while keeping independent safety-critical protection separate from normal supervisory control.

The HMI provides machine overview, operating-mode selection, alarms, trends, diagnostics and maintenance information. Normal operator screens do not provide casual editing of safety-critical trip thresholds, and loss of the HMI does not defeat independent protection or healthy automatic machine control. :contentReference[oaicite:10]{index=10}

Energy-Recovery Operation

Energy recovery is enabled only when measured hydraulic conditions show that genuine recoverable pressure head exists.

The system maintains the hydraulic conservation relationship:

Q_pump = Q_direct + Q_recovery

The recovery branch cannot be commanded above measured pump flow, and the direct hydraulic path assumes the required process duty if the turbine, PMG, rectifier or recovery controls become unavailable. :contentReference[oaicite:11]{index=11}

H.E.R.P.S therefore remains an externally powered pumping system with energy recovery from otherwise-wasted hydraulic pressure reduction; the recovery system does not create additional pump head merely to generate electrical output.

Normal Stop & Controlled Shutdown

A normal shutdown transfers the system away from recovery operation before the primary pump is brought to rest.

1. Reduce or disable hydraulic-energy recovery.
2. Transfer required process duty to the direct hydraulic path.
3. Ramp pump torque and speed down through the controlled VFD sequence.
4. Maintain required cooling for the validated post-run period.
5. Return the package to standby.

A controlled protective trip similarly prioritizes recovery disablement and process-safe direct-path operation where practical before the controlled motor rundown occurs.

Emergency Shutdown & Independent Protection

Emergency shutdown is not dependent solely on ordinary PLC or SCADA logic. Revision D uses independent hardwired protective actions layered over the normal control system. :contentReference[oaicite:12]{index=12}

The emergency-stop architecture removes or inhibits torque-producing outputs, commands the recovery subsystem toward its safe condition, preserves or establishes the required direct hydraulic path and isolates hazardous electrical energy as defined by the validated safety design.

Reset is deliberate and manual after the originating condition has been cleared; resetting an E-stop does not itself restart the machine. :contentReference[oaicite:13]{index=13}

Integrated Operating & Endurance Verification

The FAT acceptance program includes integrated operation after the individual subsystems have demonstrated readiness.

The machine is progressed through warm-up, controlled rated operation, control-mode transitions, recovery operation, direct-path fallback, energy-storage functions, normal stopping, standby and restart behaviour.

Acceptance requires the absence of unresolved leaks, overheating, abnormal vibration, uncontrolled oscillation, hardware faults or unresolved alarm/trip conditions during the defined test sequence. :contentReference[oaicite:14]{index=14}

Commissioning Completion & Final Handover

Final release is based on documented objective evidence rather than design expectation alone.

The Revision D handover process includes accepted FAT and SAT records, commissioning logs, performance reports, punch-list and NCR disposition, measured as-built configuration, controlled drawings, software and configuration backups, calibration and test records, applicable certificates, operation and maintenance information and final operating release. :contentReference[oaicite:15]{index=15}

A machine does not become a frozen production/as-built configuration merely because construction or testing has occurred. Revision D reserves final acceptance for the applicable validation, FAT/SAT and measured as-built release process. :contentReference[oaicite:16]{index=16}

Engineering Status

Revision: D R2.0

Primary Installation Authority: HERPS-VOL-20 — Assembly, Installation, Alignment & Real-World Build Sequence

Commissioning & Acceptance Authority: HERPS-VOL-22 — FAT, SAT, Commissioning & Performance Acceptance

Controls Authority: HERPS-VOL-15 — PLC, HMI, SCADA, Instrumentation & Field I/O

Operational Safety Authority: HERPS-VOL-16 — Functional Safety, Hardwired Trips, Control Modes & Cybersecurity

Status: Master Design-Development — Not IFC / Not Approved for Manufacturing