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 plants 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