The Site Acceptance Test (SAT) is a crucial process to ensure that the industrial equipment developed within the CHEERS project meets the technical and operational requirements before its final commissioning. Prior to the SAT of the equipment, which will be carried out at its final location at the Lleida WWTP, a FAT (Factory Acceptance Test) will be carried out at the SYSPRO facilities to minimise the appearance of possible operating problems. In the following paragraphs, the steps necessary to carry out the SAT on the industrial equipment used to produce SCP protein and ectoine will be described. This equipment has gas and liquid piping, various measuring instruments (pressure, temperature, pH, concentration and level), storage and feed tanks and two reactors.

In general, since gas and liquid pipelines are essential for the safe and efficient transport of fluids within the plant, they must be checked to ensure that there are no leaks and that the materials are compatible with the fluids being transported. In reference to sensors, pressure sensors must be calibrated and verified to ensure accurate readings, temperature sensors must be tested to ensure they operate within specified ranges, and pH meters must be calibrated to ensure accurate and reliable readings. Tank level sensors should be tested to ensure that they correctly detect liquid levels. Storage tanks and reactors, which are critical components in the plant, should be inspected to ensure that there is no corrosion, leaks and that all systems are functioning properly.

Steps to perform a useful SAT

1. Initial preparation

  • Review of technical documentation and specifications of the installed equipment (electrical and instrumentation schematics, P&IDs, manuals).
  • Test planning and assignment of responsibilities.
  • Visual inspection

2. Verification

  • Of piping, pumps, tanks and reactors.
  • Inspection of the installation of the measuring instrumentation (electrical and communication connections).
  • Operational Testing:
  • Perform pressure and flow tests to detect possible leaks.
  • Verify pressure, temperature, pH, concentration and level sensors.
  • Perform filling and emptying tests of the tanks and reactors.
  • Communication between controller (PLC ) and field devices.
  • Checking the display and control from HMI screens.
  • Simulation of normal and abnormal operating conditions.
  • Failure response and system recovery tests.

3. Safety Checks

  • Checking that all safety systems are operational, including safety valves and alarm systems.
  • Ensure that equipment complies with existing industrial safety regulations.
  • Verification of emergency shutdown system, alarms and notification systems.

4. Results

  • Record all test results in a detailed report.
  • Identify and document any deviations or problems encountered during testing.

5. Issues Correction

  • Implement solutions to any problems identified.
  • Perform additional testing if necessary to ensure that problems have been resolved.

6. Final Approval

  • Review the report of results with all stakeholders.
  • Obtain final approval for commissioning of equipment.

In conclusion, it should be noted that the performance of the SAT ensures that the equipment functions correctly and safely. By following the above steps, it can be ensured that the equipment complies with the technical and operational requirements, minimising risks and optimising the efficiency of the plant.