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Factory Acceptance Test (FAT) Procedure of PLC/DCS

In this article, I am talking about the Factory Acceptance Test (FAT) Procedure of PLC/DCS and How it is done step by step for PLC/DCS.

Check List of Factory Acceptance Test (FAT)

  •  Test 1 Overall System Configuration Check.
  •  Test 2 Visual Inspection
  •  Test 3 Power-up Test for Engineering and Operator Workstation
  •  Test 4 Power Up Test for Controllers
  •  Test 5 I/O Loop Testing
  •  Test 6 Engineering and Operator station Functions
  •  Test 7 Controller CPU Redundancy
  •  Test 8 Power Supply Redundancy
  •  Test 9 Diode O-ring Checking
  •  Test 10 Controller CPU Loading
  •  Test 11 Fail safe condition of IO check
  •  Test 12 Serial Communication Interface Check
  •  Test 13 Logic Check
  •  Test 14 Scan Time Check
  •  Test 15 Online Modification
  •  Test 16 System Diagnostic Function
  •  Test 17 Firmware Check

Test Procedure of FAT

Test 1: Overall System Configuration Check

Purpose of Test
To verify the system configuration with respect to the approved System Configuration drawing.

  • Test Procedure
  • 1. Check for the total number of System and Marshalling Cabinets
  • 2. Check the total number of Engineering and Operator Workstations.
  • 3. Check for the total number of Modbus TCP/IP Interface modules.
  • 4. Check for the total number of other Hardware as per the approved System Configuration and Bill of Material.


Test 2: Visual Inspection

2.1 System Cabinet and Marshalling cabinet

Purpose of Test
To perform the Visual / GA check and Internal Arrangement for the System and Marshalling Cabinets.

  • Test Procedure
  • 1. Check for a Total number of systems and marshaling cabinet as per the approved GA Drawing.
  • 2. Overall condition, dimensions, and orientation of the cabinet.
  • 3. Overall condition, alignment, or any damage.
  • 4. Check for the Total number of modules as per the approved GA Drawing.
  • 5. Check for the Quantity/Model of I/O Modules.
  • 6. Check Quantity and types of Terminal blocks.
  • 7. Check for TB LED glowing in case of fuse failure.
  • 8. Functional tests for Utility items (Fans & Lamps)
  • 9. Check for the Quantity/Model of Relays, Isolators (AI, AO, DI, DO), and Power Feed Modules.
  • 10. Wiring Check – Ferruling, size & color of wiring, Labels, markers, the proper size of lugs & terminals, cable dressing, etc.
  • 11. Spot check on loose wires.
  • 12. Earthing inside the cabinet.

2.2 Tabletop Console and Printer Table

Purpose of Test

To perform the Visual / GA check and Internal Arrangement for the Console.

Test Procedure

  • 1. Check for the Total number of consoles as per the approved GA Drawing.
  • 2. Overall condition, dimensions, and orientation of the cabinet.
  • 3. Overall condition, alignment, or any damage.
  • 4. Check for a Total number of various types of components.
  • 5. Wiring Check – Ferruling, Labels markers, color & size of wiring, the proper size of lugs & terminals, cable dressing, etc.


Test 3: Power up Test for Engineering and Operator Workstation

Purpose of Test

Power up the system and check for the healthiness of the Engineering and Operator workstations.

Test Procedure

  • 1. Ensure that Engineering and Operator workstations are connected per system configuration and have all requisite peripherals/accessories.
  • 2. Boot up the Engineering and Operator workstations as per the approved System Configuration Diagram.


Test 4: Power up Test of Controller


Purpose of Test
Power up the system and check for the healthiness of the Controller.

Test Procedure

  • 1. Verify that all the modules are installed as per the approved GA drawing.
  • 2. Verify no. of clusters.
  • 3. Verify that I/O modules are installed as per GA drawings
  • 4. Verify that controller nodes are connected to the Control network.
  • 5. Power up the controller and allow the controller to boot.
  • 6. Power up I/O modules and allow the modules to boot.
  • 7. Verify that the indicator LED on each Primary controller is AMBER.
  • 8. Verify that the indicator LED on each Secondary controller is not lit
  • 9. Verify that the dual indication LED on both controllers is AMBER.

Test 5: I/O Loop Testing


I/O Loop Testing

Purpose of Test

To verify that the I/O Allocation configuration matches with the approved I/O wiring table / IO Allocation document.

Test Procedure

Loop testing will be carried out by feeding the signal directly from marshaling. And Loop drawing will be used to identify individual loop wiring details.

  • For each loop, at least one point of the range should be checked.
  • Check operator station readings and record each observation.
  • The various loop details as mentioned below in the table along with the channel no as mentioned in I/O The allocation document shall match.

Loop TypeLoop DescriptionLoop Details
Open LoopsAnalog Input Loops Tag No
 Description/Range/Units/Alarm Limits as per Point database.
 Measured variables on 0, 50, 75, and 100 percent of input variation across the Loop Range.
 Check indication in Graphics also.
Device Loops (Digital
Input)
 Tag No.
 Description as per Instrument IO List.
 Check the Close & Open, On &Off, Run or Stop status corresponding to Energize & de-energize state of the loops.
 Check indication in Graphics also.
 Check for the alarm message in the graphic as well as the alarm list.
Device Loop (Digital
Output)
 Tag No.
 Description as per Instrument IO List.
 Check the following:
a) 0V & 24V across the loop corresponding to
Close/Stop, Open/Start Commands.
b) Check for the Continuity across the loop
corresponding to Pot-Free Signals.
Closed LoopsSimple Closed Loops Tag No.
 Description /Range/ Units/Alarm Limits / Controller Action as per Point database.
 Measured variable on 0, 50 & 100 percent of input variation across the Loop Range.
 Forced output on 0, 50 & 100 percent and
observation at Marshaling cabinets.
 Check for the PID tuning parameters.
 Ensure the AOT signal is inverted (FO) or else not inverted (FC) wherever required.
 Check for the Loop operation from Graphics.
I/O Loop Testing Check

Test 6: Engineering / Operator station Functionality

Purpose of Test

To demonstrate various features of the Engineering and Operator station.

Test Procedure

  • 1. Verify, that it is possible to monitor and operate Process types of equipment through Graphic displays.
  • 2. Verify that it is possible to change set point, mode, output, etc. for control loops.
  • 3. Create a process alarm and verify that it is available on Engineering / Operator station.
  • 4. Create a process event and verify that it is available on Engineering / Operator station.
  • 5. Create a system alarm by shutting down any node and verifying that the system alarm appears on the system alarm display.


Test 7: Controller CPU Redundancy

Purpose of Test

To demonstrate CPU redundancy for AC800M controller Node.

Test Procedure

  • 1. Verify controller subsystem nodes are already booted by checking the H/w structure in
  • 2. plant explorer (Navigate My e-plant-> Control Structure-> Root-> Control Network->, project -> Controllers on the left-hand side of plant explorer.
  • 3. Select aspect “System status on Top right-hand side of plant explorer”. Verify that Controller.
  • 4. and I/O Module status is shown with a green circle”. Also, verify system diagnostic on operator station.
  • Follow the test procedure mentioned below
  • 1. Open the Graphic page and faceplate for a control loop on the operator station.
  • 2. Press the INIT button on the primary controller (controller having “PRIM” indication Amber on controller front panel).
  • 3. Verify that the Backup controller takes over seamlessly (the backup controller will have the “PRIM” indication changed to “Amber” on the controller front panel).
  • 4. Verify there is no loss of control on the operator station.
  • 5. Verify alarm on operator station.
  • 6. Allow failed controller to boot. (“DUAL” indication will change to Amber)

Test 8: Power Supply Redundancy

Purpose of Test

To demonstrate the redundancy of Power supplies used for AC800M controllers.

Test Procedure

  • 1. Open Graphic display on operator station. Feed mA to one of the Analog tags/objects present on the graphic.
  • 2. Switch off one of the Power supplies. Verify that there is no interruption and that fed signal data is still available at the operator station and if so, switch on the power supply and perform the same operation on the second power supply.
  • 3. Verify power supply failure alarm on operator station.
  • 4. There should not be any failures in the subsystem, and it should not cause any disturbance to the uninterrupted operation of the system.
  • 5. There should not be any interruption in the operation of the controller subsystem.


Test 9: Diode O-ring Checking


Purpose of Test
To check for Diode O-ring failure and redundancy.
Test Procedure
Switch off one of the power supplies & verify that the same power supply module is not getting power through the Healthy power supply module & confirmed that reverse voltage is not available.


Test 10: Controller CPU Loading


Purpose of Test
To verify that AC800M controller CPU loading is within the permissible limit.
Test Procedure
Open Plant explorer (My e-plant). Navigate Control structure -> Root-> Control Network-> in the left-hand side of plant explorer.

Test 11: Fail safe condition of IO check


Purpose of Test
To know the values in case of Controller and Module bus Failure
Test Procedure
Verify the last known value on the AO and DO Modules.


Test 12: Serial Communication Interface Check

Purpose of Test

Verify that all CI867 modules are in running condition. Verify that all the tags are configured as per the customer Modbus list.

Procedure

Check the functionality by establishing communication with Mods can. Simulate and verify that the data is being read in the engineering station.


Test 13: Logic Check


Purpose of Test
To check the logic built as per customer Inputs and Requirements.


Test 14: Scan time check


Purpose of Test
To check the scan time configured for all types of loops Analog open, Analog Close, and digital loop as per the customer Requirement.

Test 15: Online Modification

Purpose

To demonstrate online addition, modification, and deletion of loops in the system

Test Procedure

  • 1. The below test procedure will be carried out in any of the controller modules selected randomly.
  • 2. Open Control Builder on Engineering Station.
  • 3. Select an application under which loop/object needs to be modified.
  • 4. Select any object and carry out the necessary modifications.
  • 5. Download the application to the controller.
  • 6. Open Plant explorer on the Engineering station.
  • 7. Search for the modified object in the plant explorer and verify that changes are applied to the object.
  • 8. Go offline in Project explorer on Engineering Station.
  • 9. Repeat the above steps for the newly added tags.
  • 10. Verify the availability of objects in plant explorer with the requisite configuration.


Test 16: System Diagnostic Function


Purpose of Test
To check the configuration, and system diagnostic of Process and Safety Control Systems and view the status in graphics.


Test 17: Firmware check


Purpose of Test
To check the Firmware of the communication modules and controllers.
Test Procedure Verify & note down the Latest Firmware available.

EndNote

I hope now you have an idea about the Factory Acceptance Test (FAT) Procedure of PLC/DCS.

From my side, I will try to cover all the topics in my next articles. So, stay connected.

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