Process Test System

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Prerequisites of the Commissioning Process

There various procedures those are supposed to be done prior to the actual commissioning process. The first one being the completion of the installation process that includes the installation and termination of the Electric locks, Reed switches on the door, the Card reader of each apartment. Once this is done comes the verification or the cold test.

During the cold test process there is a consultant approved cold test report that is followed. This sheet includes all the various parameters that need to be checked so as to verify and confirm the proper working of the cables associated with the safety system.

We in this process are asked to check for various resistances that for example the Reed switches, card reader offer using a simple multi-meter during the different operation modes of the system. Once it is confirmed that the resistance values are within the satisfactory margin the cold test is deemed pass with a clause stating “subject to operation of the system”.

Commissioning process….

There are various systematic procedure that is followed to set the system up and running in other words commission of the system.

The first step is to get the various Tema servers online with the centralized system or the EBI. This is carried out by getting the Tema server online with a portable laptop and adding it to the EBI itself using the configuration menu inbuilt in EBI. Each Tema Server has its unique IP address assigned to it decided prior according to the approval of the consultant. Once tema gets added to the EBI system its software needs to be updated using a programme called “pumpkin.exe”, this programme updates the current firmware of the Tema server to the current and the latest one.

After the Tema has been added to the EBI comes the turn of the RTU's namely the A01 and A08. this again are added to the EBI in some what a similar way as Tema servers were added that is using the configuration menu inbuilt in EBI for the RTU's. Here again each RTU has a unique code or ID known as the Neuron ID, which is preset for each A01 and A08 being used by the manufacturer himself. This information is both printed on the RTU as well as can imbedded into the RTU itself which can be uploaded into the system by pressing the neuron ID button present in the RTU which then displays it in the EBI interface. Here each RTU again is given a unique description approved by the consultant. Again once all RTU of that particular Tema has been added it's firmware is again updated to the latest version.

After such modules are added to the EBI we make a Test Access control card by adding its information to the EBI and grating it access to which ever door needed. This is done by simple menu available in the EBI where we choose the card and check the door we want to grant that card access to.

Now comes the process of physically testing the operation of the system.

When the system is powered up using the PSU (power supply unit) present and when the lock, card reader and reed switch receive power along with the RTU and Tema server the system is set on “ON” status. Now in a ideal case there should be a long beeping noise with a flickering of the LED on the card reader. The door should be automatically locked from the outside. The interface on the EBI of each RTU can be checked and should show status as “normal”.

Now we take a authenticated access card and show it to the card reader the present red LED should change to green and this information is sent to the EBI stating “access granted” along with the door number. Once access is granted the door unlocks and can be opened using the handle down operation. This then leads to breaking of the circuit within the reed switch which sends information to the EBI stating “Door Open”.

Possible malfunctions….

There are many possible reasons for the system not to operate in the desired way. This maybe cause of the card reader , Reed switch, Electric Lock or even the RTU and Tema server.

In case of card reader not functioning there might be a loud beep noise with the colour of the LED being in the wrong status. This maybe because the LED cable or the Buzzer input we interchanged among them in the RTU A01. This is solved easily by connecting the to the correct input points. In case there still exists a problem it might be because of a faulty card reader or faulty connection, which again can be checked by connecting that particular card reader directly to the RTU on the panel, if it works the problem lies in the connection if it still doesn't work the card reader is found to be faulty and the process is tried again with a new card reader.

In case there a issue where the door status I the EBI isn't correct might be because of the Reed Switch not working properly. This is corrected by checking the connections in the Reed Switch and the resistances connected. If a fault is found its changed immediately.

Electric locks at times also tend to be a cause to the problem. When a door id found to be unlocked when power is being supplied to it, it might be a case where the L&E status on the lock has been set to the wrong one. In such a case simple the lock is opened and the L&E status is changed. There also might be a case of faulty connection if the problem still exists where in the connections a re checked again along with the resistances or in some cases the Locks are changed for new ones if they are found to be faulty.

EBI has a inbuilt system to check for problems within the RTU where is checks for the malfunction within the RTU and if it finds any reports the same to the system interface, where if the issue is correctable the RTU is replaced with a new one.

I was given the opportunity to work for Honeywell Operations department under…………. I was asked to work with ………the project engineer at World trade center Residence. I was given on site training about the security system being installed at the site along with theory.

I got to earn in detail about the security system that Honeywell provides in the Middle East. It included the access control system, CCTV system, intrusion system and Intercom system.

It was a very educative experience to work as a “on site engineer” to learn and experience at the same time in the real site environment. I was given numerous responsibilities for the daily up keeping at the site. I was in charge of the Tag making and printing at the beginning. Later I was given other responsibilities such as performing Cold test and Commissioning process of the access control system.

During the project we were faced with many hurdles that me and my senior engineers together managed to resolve. I was involved in the approval process where in I got to meet up with the final client and got to hear their requirements which we later incorporated into our system.

I was also on a daily basis in touch with our consultant Bilt Middle East and was present at various discussions where different issues were solved regarding the project.

I also got to experience the pressure of working in a competitive environment where working within a time limit was a prime issue.

1. Cold test report

2. EBI system Menu

3. TEMA configuration Menu

4. Add TEMA server Menu

5. Add RTU A01 Menu

6. Add RTU A08 Menu

7. TEMA key hardware Menu

8. Behaviour Module Menu

9. TEMA server point detail interface

10. RTU point detail interface.

11 Alarm interface on EBI

1. Honeywell Building Solutions brochure

2. World Trade Centre Residence Technical Submittal

3. Honeywell Network data sheets

4. solutions