FACTORY ACCEPTANCE TEST DOCUMENT PROCEDURE CONTENTS INTRODUCTION GENERAL FAT SCHEDULE 1.0 1.1 1.2 1.3 1.4 HARDWARE INSPECTION OF PLC SUB SYSTEM HARDWARE CHECK/ PHYSICAL SOFTWARE PACKAGE CHECK I/O LOADING SPECIFICATION PLC START-UP AND POWER FAIL RESTART COMMUNICATION REDUNDANCY 2.0 2.1 APPLICATION INSPECTION FOR LOGIC FUNCTIONS LADDER LOGIC FUNCTIONAL CHECK AND GRAPHIC SCREEN CHECK 3.0 APPLICATION INSPECTION FOR PLC 1 PDB/ MARSHALING PANELS 3.1 GENERAL ARRANGEMENT 3.2 APPEARANCE AND CONSTRUCTION 3.3 PANEL WIRING 3.4 PANEL FUNCTIONAL CHECK 3.5 POWER SUPPLY REDUNDANCY CHECK I.INTRODUCTION The Factory Acceptance Test (FAT) is provided in accordance with the . There will be a Pre FAT where ** will check all the items are in order and record the same. After finding everything in order during Pre FAT ** shall give FAT call with signed Pre FAT document. GENERAL: 1. The Factory Acceptance Test is carried out in order to demonstrate that the system and its components function properly, that manufacturing, assembly, configuration and software generation are done correctly and that system performance is in compliance with the approved functional specifications and relevant documents. 2. Daily progress meeting will be held to check progress problems etc. 3. The documentation for F.A.T. will consist of relevant functional specifications and other approved documents. F.A.T. SCHEDULE The Electrical Engineer is responsible for the overall execution of the F.A.T. and will be the prime interface between the client inspectors and ------------------------- Engineers from the beginning to the completion of the F.A.T. 1 2 3 4 5 Date of F.A.T. Place Test Conductor Schedule of F.A.T. Test Witnessed by -------------- – Electrical engineer --------------– Instrumentation engineer 1.0 1.1 HARDWARE INSPECTION OF PLC SUB SYSTEM HARDWARE CHECK/ PHYSICAL SOFTWARE PAKAGE CHECK OUTLINE All hardware components for which test certificates exist; are subjected to complete testing before being staged for inspection. OBJECTIV E The purpose of this test is to verify test certificates for following items. 1. For Input/Output modules 2. For PLC Processor System 3. For Power Supply module REFERENC E PROCEDU RE 1. PLC System configuration/Nest Loading 2. Bill of Materials Check that test certificates are available for above items and examine test certificates and test procedures carried out. (Test certificates will be furnished during F.A.T.). CRIETERIA Test Certificates for all above components are available FOR and the components confirm to Rockwell Automation's COMPLIA Quality Standards. NCE COMMENT S 1.2 I/O LOADING SPECIFICATIONS OUTLINE OBJECTIV E All I/O Modules and Racks are assigned during detail engineering and quantity and the position of each item Installed in the I/O Rack are of utmost importance. The purpose of this test is to verify that all I/O Modules, Racks are correct in quantity and that each I/O Module is installed in the right position. REFERENC E 1. Approved PLC System configuration 2. PLC Panels General Internal Arrangement PROCEDU RE 1. Visually check that each I/O Module is installed in the correct slot and check the Module Catalog Number. 2. Visually check that each I/O Rack is correct in quantity and installed in the correct position. 3. Visually check that all labeling is in order. CRIETERIA FOR The quantity and location of the I/O Modules, I/O Racks COMPLIA are in accordance with the system configuration. NCE COMMENT S 1.3 PLC START-UP AND POWER FAIL RESTART OUTLINE PLC goes to its operating environment on powering up, provided that all interlocks are satisfied. OBJECTIV E The purpose of this test is to ensure that PLC automatically boots up when going from 'Power Off' environment to "Operating environment". PROCEDU RE 1. Power off PLC individually or the system as a whole. 2. Power on each component individually Each component boots up automatically. CRIETERIA In case of Power failure of PLC all the outputs should FOR drop and the outputs continue with their earlier state COMPLIA after Power restoration; provided all interlocks are NCE satisfied. COMMENT S 1.4 COMMUNICATION OUTLINE PLC is configured for Ethernet communication with CTech SCADA. OBJECTIV E To check whether Ethernet communication is functioning normally, when SCADA is connected with PLC. PROCEDU RE On disconection of Ethernet, the SCADA prompts communication failure message and on connection SCADA starts functioning normaly. CRIETERIA Failure of one ControlNet channel should not affect the PLC/Plant Operation COMMENT S 2.0 2.1 APPLICATION INSPECTION FOR LOGIC FUNCTION LOGIC FUNCTIONAL CHECK AND GRAPHIC SCREEN CHECK The logic generated for this project is based on plant control philosophy presented by SFC. OUTLINE Functional Test shall be performed for each type of equipments. OBJECTIV E PROCEDU RE CRIETERIA COMMENT S The purpose of this test is to verify that the logic is as per plant’s process requirement. 1. To simulate the inputs, and confirm the corresponding outputs. 2. To verify the flow of logic as per plant control philosophy. The logic generated should function as per the plant control philosophy. 3.0 3.1 APPLICATION INSPECTIONS FOR PLC PANEL GENERAL ARRANGEMENT OUTLINE OBJECTIV E Panel manufactured for this project is subjected to client's visual inspection to confirm that all components and accessories are in accordance to final approved panel specifications. The purpose of this test is to verify that the following are in accordance with approved panel drawings : 1. Visual inspection to confirm that all material is as per panel drawings. 2. Confirm that all components and accessories are mounted as per panel drawings. REFERENC Approved panel drawings E PROCEDU RE Visually check that panel based on above objectives and verify that panel is in order. CRIETERIA FOR Panel should confirm to that defined in panel drawings. COMPLIA NCE COMMENT S 3.2 APPEARANCE AND CONSTRUCTION OUTLINE Panel manufactured are certified free from scratches and any deformities which might impair the project quality and appearance. OBJECTIV E The purpose of this test is to ensure that panels are free from scratches and deformities. REFERENC Panel drawings E PROCEDU RE Visually check that all components are free from scratches and any kind of deformities. There should not be any external defects such as CRIETERIA scratches and other deformities which might impair the product quality or appearance. COMMENT S 3.3 PANEL WIRING OUTLINE OBJECTIV E Panel wiring for this project is subjected to client's visual/functional inspection to confirm that wiring done is in accordance with terminal assignment, panel drawings and wire colors as per the drawing. The purpose of this test is to verify that the following are as per drawing REFERENC E 1. Panel Power wiring drawings 2. Module wiring drawings PROCEDU RE 1. Visually/functionally check that each panel wiring based on above objectives and verify that each panel wiring is in order. 2. Check color codes/size of all wires as per approved drawings. CRIETERIA COMMENT S Wiring should be in accordance with the Terminal assignment. 3.4 PANEL FUNCTIONAL CHECK OUTLINE OBJECTIV E Panels for this project is subject to complete testing before being staged for F.A.T. Result of all checking will be recorded in internal Panel Inspection Report The purpose of this test is to verify the panels are in accordance with the following1. Panel GA Drawing 2. Panel Wiring Drawing REFERENC E 1. Panel GA Drawing 2. Panel Wiring Drawing PROCEDU RE 1. Check the Panel Inspection Report and examine each report. 2. Randomly check the Inspected Items for verification. CRIETERIA 1. All panel inspection reports are available. 2. Report of panel inspection report should show GOOD/OK. COMMENT S 3.5 POWER SUPPLY REDUNDANCY OUTLINE All 24V dc Power Supply has been provided with completed redundancy. OBJECTIV E To check whether failure of one Power Supply leaves the process unaffected and the redundant Power Supply is functioning normally. PROCEDU RE To simulate a Power Supply failure, Power supply is incoming supply is switched off. Under such an event, the redundant Power Supply should continue functioning properly without affecting the process. Failure of one Power Supply should not affect the CRIETERIA PLC/Plant Operation COMMENT S