FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
PROJECT
Wellhead Control Panel for Salam Gas Plant
FAT PROCEDURE
Rev
Date
Description
Prepared by
Verified by
Approved by
00
18-June-2023
Issued for Approval
M. Fathy
M. Shalaby
A. Alaa
01
27-July-2023
Issued for Approval
M. Fathy
M. Shalaby
A. Alaa
Page 1 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
Key Information
Customer
:
Khalda Petroleum Company
Supplier
:
Giza Systems
Project
:
Wellhead Control Panel for Salam Gas Plant
CLIENT APPROVALS
REVIEW CODE
APPROVED BY
□
WORK MAY PROCEED.
Name:
REVISE AND RESUBMIT.
WORK MAY PROCEED SUBJECT TO
INCORPORATION OF CHANGES
INDICATED.
Signature:
Date:
1
□
2
□
3
REVISE AND RESUBMIT.
WORK MAY NOT PROCEED.
□
4
REVIEW NOT REQUIRED.
WORK MAY PROCEED.
Page 2 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
TABLE OF CONTENTS
1.
GENERAL ......................................................................................................................................... 5
1.1. Introduction ........................................................................................................................................ 5
1.2. Purpose ............................................................................................................................................. 5
1.1
2.
Abbreviations ............................................................................................................................... 6
Overview ........................................................................................................................................... 7
2.1
Hardware and Standard Software Tests ....................................................................................... 7
2.2
Application Software Verification .................................................................................................. 7
3.
Pre-Requisite ..................................................................................................................................... 8
3.1
System Equipment ....................................................................................................................... 8
3.2
Documentation ............................................................................................................................. 8
3.3
Inspection and Vendor Pre-FAT Testing ....................................................................................... 9
3.4
Test Equipment ............................................................................................................................ 9
4.
Personnel Requirements .................................................................................................................. 10
4.1
VENDOR Responsibilities .......................................................................................................... 10
4.2
COMPANY Responsibilities ....................................................................................................... 10
5.
Configuration ................................................................................................................................... 11
5.1
Management / Control ................................................................................................................ 11
5.2
System Configuration ................................................................................................................. 11
5.3
Test Configuration ...................................................................................................................... 11
5.4
Simulation .................................................................................................................................. 11
5.5
6.
6.1
5.4.1
Loop Testing ....................................................................................................................... 11
5.4.2
Logic Testing ....................................................................................................................... 11
Test Database............................................................................................................................ 11
Testing ............................................................................................................................................ 12
Structured Testing - WHCP ........................................................................................................ 12
6.1.1
Test Plan ............................................................................................................................. 12
6.1.1
Test Duration....................................................................................................................... 12
3-4 working days for 1st Skid, then 1-2 working days for the remaining Skids .................................... 12
6.1.2
Test Location....................................................................................................................... 12
6.1.3
Test Schedule ..................................................................................................................... 12
6.1.4
Mandatory Functional Tests................................................................................................. 12
6.1.5
Control Strategy Verification ................................................................................................ 12
6.2
Unstructured Testing .................................................................................................................. 12
6.3
Retest Method............................................................................................................................ 13
7.
Test Documentation ......................................................................................................................... 14
7.1
Test Log..................................................................................................................................... 14
7.2
Test Result................................................................................................................................. 14
Page 3 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
7.3
8.
Test Discrepancies..................................................................................................................... 14
Problem Resolution.......................................................................................................................... 15
8.1
Resolution during FAT................................................................................................................ 15
8.2
FAT Suspension / Resumption / Restart ..................................................................................... 15
9.
Factory Acceptance Test Report ...................................................................................................... 16
10.
FAT Certificate................................................................................................................................. 17
11.
Test Forms and Record ................................................................................................................... 18
11.1
Bill of Materials Check ................................................................................................................ 18
11.2
Skid/Panels Hardware Checks ................................................................................................... 21
11.3
Laptop Hardware Check ............................................................................................................. 25
11.4
Functionality Check .................................................................................................................... 26
11.4.1 SKID-XX ............................................................................................................................. 26
11.4.1.1 Cables Megger Test ..................................................................................................... 29
11.4.1.2 Power Feeders Redundancy Check .............................................................................. 26
11.4.1.3 DCP Electrical/Mechanical Checks ............................................................................... 28
11.4.1.4 Hydraulic Panel Checks................................................................................................ 29
11.4.1.4.1. Pressure Check ............................................................................................................ 29
11.4.1.4.2. Equipment’s Checks ..................................................................................................... 30
11.5
Loop Check................................................................................................................................ 32
11.5.1 SKID-XX ............................................................................................................................. 32
12.
11.5.1.1 Analog Input ................................................................................................................. 32
11.5.1.2 Digital Input .................................................................................................................. 34
11.5.1.3 Digital Output ............................................................................................................... 35
Appendix 1 –HW IO Loop Check Record.......................................................................................... 36
13.
Appendix 2 – HMI Display Check Record ......................................................................................... 36
14.
Appendix 3 – Deficiency Log ............................................................................................................ 36
15.
Appendix 4 – DCP Continuity Record ............................................................................................... 36
Page 4 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
1. GENERAL
1.1. Introduction
Khalda Petroleum Company (KPC) is a joint venture between Apache Corp and the Egyptian General
Petroleum Corporation (EGPC). Located in the Western Desert of Egypt.
1.2. Purpose
This document defines the criteria and administrative details associated with the performance of the Factory
Acceptance Test (FAT) that will be conducted as part of the project. This document describes the
conditions, requirements, plans, procedures, success criteria and responsibilities for performance of the
FAT.
This document will be used to guide and control the performance of the FAT. It will also be used as the
basis for monitoring progress and for determining satisfactory completion of the FAT.
Page 5 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
1.1 Abbreviations
RTU
2oo3
AC
AI
AI-R
CAT 6
DC
DCS
DI
DI-R
DO
DO-R
DSA
EMI
FTE
HART
HDD
HDPB
HMI
I/O
IP
IS
LED
NEMA
Non-IS
PC
PCI
PV
RAID
RAM
RDIMM
RH
RTD
SCADA
STP
TCP/IP
UPS
USB
DCS
FAT
F&G
HART
HCF
IOM
SAT
Remote Terminal Unit
2 out of 3
Alternating Current
Analogue Input
Analogue Input – Redundant
Category 6
Direct Current
Distributed Control System
Digital Input
Digital Input – Redundant
Digital Output
Digital Output – Redundant
Distributed System Architecture
Electromagnetic Interference
Fault Tolerant Ethernet
Highway Addressable Remote Transducer
Hard Disk Drive
Horizontal DC Power Bus bar
Human Machine Interface
Input/Output
Ingress Protection or Internet Protocol
Intrinsic Safety
Light Emitting Diode
National Electrical Manufacturers Association
Non-Intrinsically Safe
Personal Computer
Peripheral Component Interconnect
Process Variable
Redundant Array of Independent Disks
Random Access Memory
Registered Dual Inline Memory Module
Relative Humidity
Resistance Temperature Detector
Supervisory Control and Data Acquistion
Shielded Twisted Pair
Transmission Control Protocol / Internet Protocol
Uninterruptable Power Supply
Universal Serial Bus
Distributed Control System
Factory Acceptance Test
Fire and Gas
Highway Addressable Remote Transducer Protocol
HART Communication Foundation
Input/Output Module
Site Acceptance Test
Table 1 Abbreviation Table
Page 6 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
2. Overview
The Factory Acceptance Test consists of the following phases:
2.1 Hardware and Standard Software Tests
•
•
•
•
Visual inspection of the Hardware for conformance to drawings, appearance of equipment and part
numbers in accordance with Bill of Materials.
Fault Recovery Tests will be conducted as defined in this document.
Demonstration of the proper functioning of all hardware and standard software functions using
functional tests defined in this document.
Earthing and Power Up checks for all hardware.
2.2 Application Software Verification
•
•
•
•
•
•
•
Verification of the Network Configuration
Point database
Control Schemes
Logics tests
HMI
Graphic Displays & Display Navigation
Offline configuration database checks
Page 7 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
3. Pre-Requisite
3.1 System Equipment
The following equipment will be tested during the FAT:
• Skid
• RTU Panel including HMI
• Engineering Laptops
• DC panel
• Hydraulic panel
3.2 Documentation
The FAT will be conducted based on the following documents.
Document Number
Document Description
1. IDS0223-DWG-300
System Overview
2. IDS0223-ENG-200
RTU Bill of Materials and Datasheets
3. IDS0223-ENG-210
Hydraulic Bill of Materials and Datasheets
4. IDS0223-ENG-220
Solar Bill of Materials and Datasheets
5. IDS0223-CLC-400
Solar Calculations
6. IDS0223-CLC-410
Hydraulic System Calculations
7. IDS0223-ENG-210
Hydraulic Function diagram (P&ID)
8. IDS0223-DWG-310
Skid Layout
9. IDS0223-DWG-320
RTU Panel GA&IA drawings
10. IDS0223-DWG-330
Power Panel GA&IA drawings
11. IDS0223-PRC-500
FAT Procedure
Page 8 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
3.3 Inspection and Vendor Pre-FAT Testing
VENDOR will conduct Pre-FAT as per approved FAT procedure for Hardware and Software configuration.
Pre-FAT will be trial run of the FAT. Deficiency Log will be generated and addressed if any deficiency found.
Before commencing the FAT activities, the Skid/PLC/DCP/HP Panels will be installed with earth/grounding
cables and communication cables connected, powered up and Pre-FAT tested. Inspection will be
conducted before FAT as per COMPANY Inspection form.
Pre-FAT records will be generated based on the test results. VENDOR will maintain the deficiency / action
list until all items have been resolved. Pre-FAT results will be compiled and submitted at the time of SRR
(System Readiness Review). SRR will be planned and conducted after completion of Pre-FAT and prior to
FAT. SRR will be successfully completed after written confirmation from COMPANY on deficiency / action
list.
WHCP will be verified as being ready for formal testing as a requirement of the SRR. After inspection and
successful completion of SRR, system will be ready for FAT.
3.4 Test Equipment
During FAT, the following test equipment, calibrated in accordance with international standards, will be used
to simulate the process variables or to measure output values.
Equipment
Quantity
Digital Multi-meter
3
4-20 ma DC current source
3
Megger cables Tester
1
Table 2 List of Test Equipment
Page 9 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
4. Personnel Requirements
4.1 VENDOR Responsibilities
VENDOR will provide the personnel, documentation and approved test equipment to conduct the Factory
Acceptance Test. Technical personnel from the vendor’s engineering team will be responsible for running
structured tests. The personnel shall be capable of determining and resolving the root cause of any
technical problem encountered during FAT, within the scope of FAT.
VENDOR Personnel:
• Project Manager: Project Management
• Team Leader: FAT Management
• Engineering Team: Running tests and resolving problems
• Technicians: Electrical wiring connections
4.2 COMPANY Responsibilities
COMPANY will provide sufficient personnel familiar with the plant operations and instrumentation to witness
tests performed by VENDOR in accordance with approved test procedures. The personnel made available
must be authorized to sign acceptance at each stage of testing.
COMPANY Personnel:
• Responsible Test Witness Leader
• Responsible Test Witness Engineers
Page 10 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
5. Configuration
5.1 Management / Control
The FAT will be conducted as per the approved FAT procedure. Each action will be performed as indicated
in the test procedure. Results will be documented as an observation. For all successful tests, the test sheet
will be marked as “OK”.
Changes to hardware and software will be documented in the deficiency Log sheet. The deficiency log
sheet will be attached to the test sheets and will comprise a complete record of all observation during FAT.
5.2 System Configuration
The following equipment will be tested for complete Hardware and Software functionality:
• Skids
• RTU Panels
• HMI
• Hydraulic Panels
• Power Panels
5.3 Test Configuration
For any configuration change during FAT like Hardware/Software configuration deviation, operation and
performance deviation will be documented in sufficient detail. The effect of each deviation and requirements
will be described in detail.
The following items will be included:
• Hardware / Software Configuration deviation
• Operational and performance deviations
• Reason for each deviation and affected requirements
5.4 Simulation
Since an entire set of actual field devices cannot be connected and used for process simulation during FAT,
simulation equipment will be used for unconnected Hardwired IOs.
5.4.1
Loop Testing
All I/Os will be tested using the following simulation equipment:
• AI simulation: 4-20 mA generator
• DI simulation: Jumper
• DO simulation: Multi-meter
5.4.2
Logic Testing
During logic testing, analogue and digital inputs/outputs will be simulated from the system.
5.5 Test Database
The FAT will be conducted with the latest approved database from the COMPANY. Any database change
during FAT will be documented with sufficient details. The effect of each deviation and requirement on
system performance will be studied and described in details. This includes replacement / addition / deletion
of tags / tag parameters.
Page 11 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
6. Testing
The system to be tested during FAT comprises of all Hardware and Software as per the approved Bill of
Materials documents and approved configuration design from COMPANY.
The equipment will be staged and integrated in accordance with the minimum system architecture
requirements.
6.1 Structured Testing - WHCP
Test Plan
6.1.1
The structured testing will be conducted as per test forms given in Appendix 01 to 5.
6.1.1
Test Duration
6.1.2
Test Location
10-15 working days
The test shall be held at Giza Systems’ FAT Area located in Ismailia Free Zone, Ismailia, Egypt.
Test Schedule
6.1.3
The daily FAT schedule shall be as follows:
From
8:00 AM
8:30 AM
12:00 PM
1:00 PM
4:30 PM
To
8:30 AM
12:00 PM
1:00 PM
4:30 PM
5:00 PM
Activity
Daily Activity Review
Testing
Lunch Break
Testing
Progress Review for the Day
Table 3 Test Schedule
6.1.4
Mandatory Functional Tests
The following will be the mandatory tests during the FAT:
•
•
•
•
Visual Inspection
Power supply redundancy test
Loop Test
Hydraulic panel functionality
6.1.5
Control Strategy Verification
Control Strategy Verification will be performed by using simulation software. Simulation software will
simulate field signals, to verify configuration of control strategies as per approved design input.
6.2 Unstructured Testing
Any unstructured test or any test outside the approved FAT procedure will be conducted after FAT
conclusion. The effect of any unstructured test on system performance will be studied and discussed before
performing any such test.
Page 12 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
6.3 Retest Method
Any discrepancy found during testing, will be corrected by VENDOR Engineers. The retest will be
conducted as per FAT procedure.
Page 13 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
7. Test Documentation
7.1 Test Log
All identified tests will be performed 100% to ensure the integrity of Hardware and Software. Each action
will be performed as indicated in the test procedure with the result observed. The FAT Test Sheets will be
marked “OK” for each successful test and will be marked “NOT OK” for any unsuccessful test and an entry
will be made in the Deficiency Log Sheet.
7.2 Test Result
At the end of the FAT, the hardcopy of Deficiency Logs & Test Sheets will be generated as a FAT record.
All test results / records will be signed by VENDOR and COMPANY representatives.
7.3 Test Discrepancies
FAT discrepancies will be documented in the form of FAT Deficiency Log Sheet. The Deficiency Log will
note the date of occurrence of a problem, problem report number, description of problem, action taken to
correct the problem, status of resolution, and date of resolution. Deficiency log will also record all changes
to hardware and software. Copy of deficiency log will be included in Final FAT document. The format of the
deficiency log sheet will be provided at the time of FAT.
Page 14 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
8. Problem Resolution
8.1 Resolution during FAT
The FAT will be performed as per approved FAT procedure. Test discrepancy observed during the test will
be logged in Deficiency Log Sheet.
If the deficiency is due to VENDOR, VENDOR engineer will rectify the fault. Status will be updated to
COMPANY to enable them to repeat the test. Acceptance of deficiency rectification will be signed by
COMPANY and VENDOR authorized representatives. If the above mentioned re-test fails, then this test will
be rescheduled at a later time. On successful completion of a test, the test sheet will be marked as “OK”.
If the deficiency is due to new requirements from the COMPANY, it will be recorded in the log sheet as ‘Not
in Scope’. If VENDOR accepts to implement the same, it will be recorded as ‘Accepted’, and if not
accepted, the same will be recorded as ‘Not Accepted’. For such additional customer requirement, a formal
Change Order Log will be raised, as defined in contract, to identify the time impact and cost impact
wherever applicable.
All parties will agree the Deficiency Logs and Change Order Log and depending upon the scale of the
change it will either be implemented before the end of the FAT, or completed on site
8.2 FAT Suspension / Resumption / Restart
If it is seemed impossible to continue the test, the test will be terminated. If, on the contrary, it is possible to
continue, a new test date will be scheduled. If the test is not acceptable, the test sheet will not be signed off.
Page 15 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
9. Factory Acceptance Test Report
Upon successful completion of all tests, COMPANY and VENDOR authorized representatives will sign an
Acceptance Certificate.
The Deficiency Log will be attached to the test sheets and will comprise a complete record of all faults
discovered during the FAT.
The following records will be generated during the FAT:
• FAT Certificate
• Deficiency Log
• Test Sheets
• Final FAT meeting MOM
• Copy of Markups
Page 16 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
10. FAT Certificate
Giza Systems
FACTORY ACCEPTANCE TEST CERTIFICATE
THE UNDERSIGNED HAS INSPECTED AND TESTED THE
WELL HEAD CONTROL PANEL
AND ACCEPTS THAT THE RTU
MANUFACTURED FOR
WELLHEAD RTU FOR SALAM PLANT
HAS BEEN BUILT TO THE AGREED SPECIFICATIONS, VARIATIONS
AND
IS FULLY FUNCTIONING TO MEET THE REQUIREMENTS
OF
CUSTOMER P.O NO. 85798
FAT LOCATION : Giza Systems Free Zone (Ismailia)
Start Date
End Date
--------------
------------
For
For
KPC
Giza Systems
Title:
Title:
Date:
Date:
Page 17 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11. Test Forms and Record
11.1
Bill of Materials Check
Skid/Hydraulic Panel Bill Of Materials
Purpose
The purpose of this test is To verify that all Hardware ordered for the project is
available installed
Pre-requisite
Approved Bill Of Materials Document shall be available
Reference Document
System Architecture
Skid Layout
RTU Bill of Materials
Hydraulic Panel Bill of Materials
DCP/Solar System Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Visually examine of all materials in
accordance with Bill of Material document.
Upon visual inspection the verified items will
be marked in the BOM document
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 18 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
Power Panel & Solar System Bill Of Materials
Purpose
The purpose of this test is To verify that all Hardware ordered for the project is
available installed
Pre-requisite
Approved Bill Of Materials Document shall be available
Reference Document
System Architecture
Skid Layout
RTU Bill of Materials
Hydraulic Panel Bill of Materials
DCP/Solar System Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Visually examine of all materials in
accordance with Bill of Material document.
Upon visual inspection the verified items will
be marked in the BOM document
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 19 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
RTU Panel and Laptops Bill Of Materials
Purpose
The purpose of this test is To verify that all Hardware ordered for the project is
available installed
Pre-requisite
Approved Bill Of Materials Document shall be available
Reference Document
System Architecture
Skid Layout
RTU Bill of Materials
Hydraulic Panel Bill of Materials
DCP/Solar System Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Visually examine of all materials in
accordance with Bill of Material document.
Upon visual inspection the verified items will
be marked in the BOM document
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 20 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.2
Skid/Panels Hardware Checks
Skid -- of 26
Purpose
To verify that the skid including the Hydraulic, DCP, and PLC panels are built as
per approved skid layout and GA&IA drawings and components are configured
and supplied in accordance with the hardware manufacturing specifications.
Pre-requisite
Hardware and Approved drawings issued for construction shall be available
Reference Document
System Architecture
Skid Layout
RTU Panels drawings
Power Panel Drawing
Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
1.2
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Verify Skid Hardware and design is as per
approved Drawings
Verify Bill of Material (BOM)
1.3
Verify Skid Exterior free of significant
marks/scratches
1.4
Verify proper opening and closing of doors and
handle
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 21 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
RTU -- of 26
Purpose
The purpose of this test is to verify and document that all the Hardware are
installed
Pre-requisite
Hardware and Approved drawings issued for construction shall be available
Reference Document
System Architecture
RTU Panels drawings
Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
1.2
1.3
1.4
1.5
1.6
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Verify Panel Hardware and design is as per
approved Panel Drawings
Verify Bill of Material (BOM)
Verify Panel Exterior free of significant
marks/scratches
Verify proper opening and closing of doors and
handle locks
Verify Panel and all components are correctly
labelled
Check the distribution of System Power (12V
DC) and (24V DC) Power
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 22 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
Power Panel -- of 26
Purpose
The purpose of this test is to verify and document that all the Hardware are
installed
Pre-requisite
Hardware and Approved drawings issued for construction shall be available
Reference Document
System Architecture
Power Panels drawings
Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
1.2
1.3
1.4
1.5
1.6
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Verify Panel Hardware and design is as per
approved Panel Drawings
Verify Bill of Material (BOM)
Verify Panel Exterior free of significant
marks/scratches
Verify proper opening and closing of doors and
handle locks
Verify Panel and all components are correctly
labelled
Check the distribution of System Power (24V
DC) Power
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 23 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
Hydraulic -- of 26
Purpose
The purpose of this test is to verify and document that all the Hardware are
installed
Pre-requisite
Hardware and Approved drawings issued for construction shall be available
Reference Document
System Architecture
Skid Layout
Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
1.2
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Verify Panel Hardware and design is as per
approved Panel Drawings
Verify Bill of Material (BOM)
1.3
Verify Panel Exterior free of significant
marks/scratches
1.4
Verify proper opening and closing of doors and
handle locks
1.5
Verify Panel and all components are correctly
labelled
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 24 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.3
Laptop Hardware Check
EWS- -- of 4
Purpose
The purpose of this test is to verify and document that all the Work station
PC/Laptop Hardware are installed, configured and working properly
Pre-requisite
Windows 10 Operating System must be loaded on all the Work station
PC’s/Laptops
Reference Document
System Architecture
Bill of Materials
Test Procedure
Required
TEST Result
No.
Test#
1
1.1
Verify Manufacture , Model
no
SIMATIC Field
PG M6 Comfort
1.2
Verify Hard disk Capacity and
specifications
512 MB
1.3
1.4
1.5
Detail Test Item
Verify RAM details
Verify presence of DVD Drive
Verify operating system
OK
OK with
Comments
NOK
RTST
OK
8GB
Win 10
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 25 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.4 Functionality Check
11.4.1
SKID-XX
11.4.1.1
Cables Megger Test
Skid – of 26
Purpose
The purpose of this test is to verify that all cables (power and control cables)
insulation is working properly.
Pre-requisite
Power Panel Drawing and RTU Panels drawings shall be available.
Reference Document
System Architecture
Power Panel Drawing
RTU Panels drawings
Test Procedure
TEST Result
No.
Test#
1
1.1
1.2
1.3
1.4
1.5
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Disconnect the cable wires from both ends.
Connect one of the megger’s leads to a
ground connection.
Connect the other megger lead to the cable
conductor.
Apply the required voltage.
Record the ohm reading appears in the
megger device.
Apply this test for all cables.
1.6
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 26 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.4.1.2
Power Feeders Redundancy Check
RTU – of 26
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the Power supply redundancy is working
properly
Controller & Station must be Energized.
Test Procedure
No.
Test#
1
1.1
TEST Result
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
In the System Panel, verify that the power
LED of Controller is healthy.
1.2
Switch off the Primary Power feeder and
verify that system is healthy and still working
1.3
Note the power supply failure alarm.
1.4
Repeat above steps for Redundant Power
Supply.
1.5
Repeat above steps for Redundant Power
Supply.
1.6
Switch off both the power feeders. Observe
that the Controller configuration is retained by
the Memory Backup.
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 27 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.4.1.3
DCP Electrical/Mechanical Checks
DCP -- of 26
Purpose
The purpose of this test is to verify that the electrical data of the low voltage
panel as per design
Pre-requisite
Two Temporary feeders to be connected (24 Vdc and 220Vac)
Reference Document
Power Panel Drawings
Power Panel/Solar System Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
1.2
1.3
2
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Visual Tests
Labels Inspection
Wiring and connections inspection
As per attachment -5
Bus-bars and cables sizes inspection
Mechanical Test
2.1
2.2
Check Circuit Breakers Operation –ON, OFF and
Manual TRIP
Check Power Terminal and Auxiliary Contact
3
Electrical Function Test
Electrical test function of all switching devices.
Function test of measuring meters and protection
devices
3.3
Test control, tripping, closing, Manual/Auto
transfer
Purpose: Overall acceptance of this module by Customer
3.1
3.2
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 28 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.4.1.4
11.4.1.4.1.
Hydraulic Panel Checks
Pressure Check
Hydraulic Panel – of 26
Purpose
The purpose of this Test is to make sure that there is no leakage from any
connection.
Pre-requisite
Temporary feeders to be connected (24 Vdc)
Reference Document
WHCP Function diagram
Accumulators sizing calculation
Hydraulic Panel Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
Detail Test Item
OK
OK with
Comments
NOK
RTST
OK
Blind all the outlet pressure connections to the
wellhead valves.
1.2
Fill the panel reservoir with about 20-gallon
of the suitable hydraulic oil while observing
both Level transmitters reading.
1.3
Make sure that all isolating valves are
opened.
1.4
Make sure that the circulation valve is
closed.
1.5
Put the Motor A-O-M manual switch on OFF
Position.
1.6
Connect the supply power to the pump
motor.
1.7
Start the pump (Manually & Automatically) and
observe the increasing in the hydraulic pressure
and make sure that there is no leakage from any
connection.
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 29 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.4.1.4.2.
Equipment’s Checks
HP-01
Purpose
The purpose of this Test is to check the function of the valves, pressure
transmitters, Accumulators and pumps.
Pre-requisite
Temporary feeders to be connected (24 Vdc)
Reference Document
WHCP Function diagram
Hydraulic Panel Drawings
Accumulators sizing calculation
Hydraulic Panel Bill of Materials
Test Procedure
TEST Result
No.
Test#
1
1.1
1.2
Detail Test Item
Clear all PSD or ESD from the PLC panel.
At the starting duty pump will automatically start
according to the action of the Low Low-pressure
set point.
1.3
Pump should stop when the pressure reach the
High pressure set point.
1.4
Decrease the pressure till the Low pressure set
point, Duty pump should start.
1.5
After increasing the pressure again, slowly open
venting point and observe the performance of the
accumulators for compensating the hydraulic
pressure leakage.
1.6
Adjust the medium pressure regulators at 3000
PSI (one by one) while observing both Pressure
transmitter & Gauge reading. Leave only one
regulator in service & isolate the other one by
closing its inlet & outlet valves.
1.7
Adjust the Logic pressure regulators at 80 PSI
(one by one) while observing both Pressure
transmitter & Gauge reading. Leave only one
regulator in service & isolate the other one by
closing its inlet & outlet valves.
1.8
Charge the fusible loop by pushing the Push to
charge pilot valve and observe both pressure
transmitter & Gauge reading.
1.9
Open all of SCSSV , SSV & Wing by pulling its
pilot valve and observe its pressure transmitter &
Gauge reading and adjust the hydraulic timer.
1.10
Simulate the different remote shutdown signals
to the panel and observe the hydraulic pressure
to Wing , SSV and SCSSV accordingly.
1.11
Try to increase the hydraulic pressure again by
using the hand pumps test both safety valves.
1.12
Make sure that the pumps can started / stopped
manually.
Purpose: Overall acceptance of this module by Customer
Page 30 of 36
OK
OK with
Comments
NOK
RTST
OK
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 31 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.5 Loop Check
11.5.1 SKID-XX
11.5.1.1
Analog Input
Analog Input Loop Check
Purpose
Pre-requisite
Reference Document
No
Test#
The purpose of this test is to verify that each Analog input is configured and working
properly.
The Station must be Open.
KPC Hardwired I/O List
Interconnection Cable Schedule
MTU/RTU Internal Wiring
Appendix 1 –HW IO Loop Check Record
Test Procedure
TEST Result
Detail Test Item
Pre-FAT
OK
1
1.1
Open the graphic display in both Machine and HMI
for desired Analog Input in the station.
1.2
Check the reading on the other side (Hydraulic,
DCP, RTU panel) or Connect the signal simulator
to the terminals corresponding to the selected
Analog Input signals as per the wiring details.
1.3
Disconnect the knife edge and Verify and record
values of the alarm that appear on the alarm
summary (tag, priority and alarm value).
The following steps in case of connecting the
simulator
1.4
Supply a 4mA signal input with the current source
to simulate the 0% value of the input range. Verify
that the point value is equal to the Expected Value
at 0% and the correct units are displayed.
1.5
Repeat above step with 8, 12, 16 and 20mA
signals.
1.6
Simulate a signal that will cause the value of the
point to rise above the high alarm limit (if
applicable) by 5%. Verify and record values of the
alarm that appear on the alarm summary (tag,
priority and alarm value).
Simulate as per above step for low alarms.
1.7
Check the related alarms and events in the
alarm/event window
1.8
Repeat above steps for all Analog Inputs.
Purpose: Overall acceptance of this module by Customer
Page 32 of 36
NOK
FAT
RTST
OK
OK
NOK
RTST
OK
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
Comments:
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 33 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.5.1.2
Digital Input
Digital Input Loop Check
Purpose
The purpose of this test is to verify that each Digital input is configured and working
properly.
The Station must be Open.
Pre-requisite
Reference Document
No.
Test#
KPC Hardwired I/O List
Interconnection Cable Schedule
MTU/RTU Internal Wiring
Appendix 1 –HW IO Loop Check Record
Test Procedure
Detail Test Item
OK
1
TEST Result
Pre-FAT
NOK
FAT
RTST
OK
OK
NOK
1.1
Open the graphic display in both Machine and
HMI for desired Digital Input in the station.
1.2
Check the position of the DI on the other side
(Hydraulic, DCP, RTU panel) or Connect a
jumper to the terminals corresponding to the
selected Digital Input signals as per the wiring
details.
1.3
At this point the digital input is set to CLOSE.
Verify that the observed status is equal to the
expected. Record the status displayed on the
form.
1.4
Disconnect the jumper from the terminals. At this
point the digital input is set to OPEN. Verify that
the observed status is equal to the expected.
Record the status displayed on the form.
1.5
Verify alarms, if the digital input is configured for
alarms as required.
1.6
Check the related alarms and events in the
alarm/event window
1.7
Repeat the above steps for all the Digital inputs
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 34 of 36
RTST
OK
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
11.5.1.3
Digital Output
Digital Output Loop Check
Purpose
The purpose of this test is to verify that each Digital output is configured and
working properly.
The Station must be Open.
Pre-requisite
Reference Document
KPC Hardwired I/O List
Interconnection Cable Schedule
MTU/RTU Internal Wiring
Appendix 1 –HW IO Loop Check Record
Test Procedure
TEST Result
No.
Test#
Detail Test Item
Pre-FAT
FAT
RTST
RTST
OK NOK
OK NOK
OK
OK
1
1.1
Open the graphic display in both Machine
and HMI for desired Digital Output in the
station.
1.2
Check the status of the DO on the other side
(Hydraulic, DCP, RTU panel) or Connect a
Multimeter to the terminals corresponding to
the selected Digital Output signals as per the
wiring details.
1.3
Open the corresponding Control Module
point detail display for the selected Digital
output point.
1.4
Force the output signal to ON. Verify that the
observed value is 24V DC. Record the value
displayed on the digital Multi-meter on the
form.
1.5
Repeat above step with output signal as
OFF. Verify that the observed value is 0V
DC. Record the value displayed on the digital
Multi-meter on the form.
1.6
Repeat the above steps for all the Digital
outputs
Purpose: Overall acceptance of this module by Customer
Comments:
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
……………………………………………………………………………………………………………………………
Signatures:
KPC : …………………………………………………………………………………………………………
Giza Systems : …………………………………………………………………………………………………………
Date
: …………………………………………………………………………………………………………
Page 35 of 36
FAT PROCEDURE
Customer: Khalda Petroleum Company
Giza Project No.: GSFZP01126
Customer PO NO.: 85798
Document No.: IDS0223-PRC-500
Project Title: Wellhead Control Panel for Salam Gas Plant
Revision: 1
12. Appendix 1 –HW IO Loop Check Record
The detail list will be provided during FAT.
13. Appendix 2 – HMI Display Check Record
The detail list will be provided during FAT.
14. Appendix 3 – Deficiency Log
15. Appendix 4 – DCP Continuity Record
The detail list will be provided during FAT.
Page 36 of 36