6-ITB-26-00393 Attachment B - Control Panel Factory Acceptance Test Procedure.pdf

Attachment B

CONTROL PANEL

FACTORY ACCEPTANCE TEST PROCEDURE

Testing Overview:

The objective of this document is to:

Provide a working set of guidelines that establish a logical testing sequence.

Establish an orderly plan that will assure that all equipment provided was produced to meet or exceed expectations for a trouble free system.

Provide a traceable verification path for all tests conducted.

Provide a means of verifying the resolution of any discrepancies found.

Provide definition of objective, methodology and procedure for each test and note the equipment and software required for each test.

Provide the documents to record compliance and customer agreement with the satisfactory completion of each test.

Each following section defines the test to be conducted, each test defines the way it will be conducted, the expected results, and the way any discrepancies will be resolved. The test plan contains:

Test check lists and sign-off forms

Discrepancy forms

Factory Acceptance Test (FAT) Procedures:

Test objective:

To prove proper construction of the control system per the panel drawings and specifications.

The extent of the testing will be directed by the Owner as indicated in the following procedures. Test instruments such as calibrated analog simulators may be used to verify signals if field signals are unavailable or not required.

The extent of the tests will vary based on the type of control panel, location of fabrication, capability of the fabricator to simulate power and signals, availability of other control system equipment such as HMI servers, networking equipment and other control panels, and other project specific requirements. The owner will dictate the level of testing, what components need to be involved and who is required to witness the tests.

Test procedures will include:

Component operability Battery back-up system testing I/O simulation and communications between the Operator interface(s) and the PLC.

Tests to be conducted as applicable:

Component operability The UPS or Battery Back-up The Operator Interface(s) and associated equipment The PLC control panel(s) Discretionary Tests conducted by Engineer or Owner

Required Documents:

Control Panel Schematic Drawings.

Engineering specifications.

Discrepancy Report Form (attached)

Representatives to be present:

Panel Fabricator’s representative (required) Engineer’s representative (at owner’s discretion) Owner’s representative (at owners discretion)

Required Equipment:

A computer with the appropriate vendor supplied PLC programming software loaded and operational. Verify with the Owner the proper firmware and software versions (if required).

All PLC panel(s) operational All OIT(s) and HMI(s) operational (if required) Proper firmware version loaded into the PLC.

HMI’s and OIT’s interconnected Completed PLC Logic loaded into PLC’s, all HMI’s and OIT’s interconnected.

A power source equal to the main voltage necessary to supply the panel in its final installed state.

Set of spare fuses of each type.

Insulated alligator clip test leads (2-red, 2-black).

Analog output test load resister (250 Ohm ¼ watt).

4-20mA source for testing analog inputs.

VOM and /or continuity tester.

All tests will be conducted by qualified personnel.

The sub-systems will be interconnected on a temporary basis to provide full functionality.

All systems will be powered at various stages of the testing.

Note any serious discrepancies using a copy of the discrepancy sheet provided; resolve the discrepancy and continue. Good judgment in the use of discrepancy reporting by the test technician is expected. Minor problems on start-up and preliminary testing are expected. As a general rule, lesser problems should be resolved on the spot. For example: If a labeling problem is found it should be corrected manually and then reported for later permanent correction in order to facilitate the testing schedule.

The system will be set up and the following tests will be performed (if applicable).

1. Wiring verification

2. Point to ground short test

3. Power Source verification

4. Systematic start-up of main internal power systems

5. System voltage tests of sub assembly devices

6. Internal DC power supply tests

7. Automatic UPS back-up supply switch-over test

8. Processor DC supply tests (if applicable)

9. Processor status tests

10. PLC module start-up tests

11. Discrete I/O tests

12. Analog I/O tests

13. Communications tests including alarm status and process logic operation during failure

14. SCADA/HMI response tests including full process functionality

15. 72 hour (3 day) Burn-in test

The UPS shall be powered-up without a load for 24 continuous hours to provide sufficient time to charge the batteries.

Sign-Off:

Review of test records and discrepancies, if any are found.

If there are any discrepancies, they must be resolved or an agreed resolution must be recorded on the - Discrepancy Report Form.

Complete the Sign-off sheet at the end of this document.

Factory Acceptance Test (FAT) Checklist the following will be performed on each of the panel types

□ – Unwitnessed Factory Test

□ – Factory Acceptance Test

Panel Fabricator Representative

Engineer Representative

Owner Representative

All tests will be conducted by qualified personnel.

Aspects and components to be tested:

Item 1. The input power Item 2. The UPS Item 3. The operator control console Item 4. The PLC / termination panel

Preliminary Checks (power off)

6.) All conductors on the equipment and in test set-up have been checked for :

No reversals of L1 and AC Com.

All wires on panel are correctly marked Device terminal to wire numbers have been verified Termination of wires has been checked: tightness and Quality All AC wiring on the panel has been verified Continuity check: point to point has been completed Continuity test was marked off on Schematic copy All circuits opened for testing have been restored

7.) A complete point-to-point continuity test has been performed. This includes all wires in the panel including power, I/O, intermediary wires and all surge suppressors to ground.

1.) All equipment required in the Test procedure is present 2.) All Documents required in the Procedure document, are present 3.) All previous Discrepancies noted or logged have been resolved 4.) All equipment to be tested has been checked for physical damage 5.) All Equipment to be tested complies with specified UL Requirements

Power Tests

8.) Input Voltage test

All Modules and Processors are backed out of all racks

All Modules are disconnected from the backplane

UPS Disconnect is open at input and output

Main circuit breaker is open All subsystem and secondary fuse blocks or circuit breakers are open Voltage at Service panel is 110 VAC Voltage on the line side of the main circuit breaker is 110 VAC Voltage from AC Com to GND is 0 VAC

9.) Subsystem Circuit Breaker, fuse and voltage tests and 24VDC supply test.

Close main circuit breaker Voltage on the line side of all subsystem and secondary fuse blocks or circuit breakers is 120 VAC

Close each secondary fuse block and circuit breaker and verify there is 120 VAC on the load side of each

Verify 24VDC Power Supply is powered-up Verify 24VDC voltage on the output of the 24VDC Power Supply Close secondary fuses or breakers on the load side of the 24VDC Power Supply Verify 24VDC voltage on the load side of all secondary fuse blocks or circuit breakers

10.) PLC status check Verify PLC Power Supply is off Push the PLC processor into position in the PLC rack Verify connection of communications lines as shown on the block diagram.

Apply 110VAC to the PLC power supply.

Observe the status indicators on the PLC. (If a configuration error occurs, shut off power plug in all I/O modules and observe again). Verify proper status indications per manufacturers recommendations

PLC Panel Discrete I/O Tests

*** Verify that the power from all sources is “off”. CAUTION! This system is powered by a UPS, cutting the power source to the UPS will not disconnect power from “Down line circuits! You must unplug from the UPS output to isolate the down-line circuits***

11.) Using a VOM in a NON-auto mode, test the AC voltage from the main circuit breaker to N and Ground. If any voltage is present do not continue until these circuits are dead.

Turn off any PLC DC power supply switches.

A.) Verify connection of the monitoring computer; it must be capable of observing the PLC data table.

B.) Power –up the monitoring computer

C.) Turn the main power on.

D.) Turn the PLC power switches and DC supply switches on.

E.) Establish communications with the PLC

F.) Verify that the PLC is operating and the I/O present no errors (look at the error word and the status word in the data table)

G.) Verify that the UPS has powered up and is charging

12.) Discrete Input Test:

A.) For the discrete input points in the Control Panel Schematic Drawings – one-by-one jumper the corresponding terminals on the I/O terminal strip.

B.) Verify that shorted terminals read logic “1” in I table of PLC programming software, and verify that open terminals read logic “0”.

C.) For HMI, verify that point in point control test panel reads a logic “1” when shorted at RTU, and reads a “0” when open. Verify that graphic screen displays appropriate state.

D.) Indicate that the tests for each I/O point passed by initialing next to each I/O point on the Control Panel Schematic Drawings pertinent to these I/O points. A representative from each participant should initial (panel fabricator, integrator, engineer, owner).

Verify all points have been successfully tested

13.) Discrete Output Test:

A.) For each discrete output in the Control Panel Schematic Drawings, force each bit “on” and “off” using the PLC software. Observe on the output module, in the appropriate PLC table and on the HMI screen that the intended bit went on and off.

B.) Verify that output point changes state when the bit is forced in the PLC. The change of state will depend on the type of output module. For 120 VAC modules, 120 VAC should be present on the terminal when the output is forced “on” and 0 VAC should be present on the terminal when the output is forced “off”. For 24 VDC modules, 24 VDC should be present on the terminal when the output is forced “on” and 0 VAC should be present on the terminal when the output is forced “off”. For contact output modules, there should be electric continuity present between the output terminals when the output is forced “on” and an open circuit should be present between the output terminal when the output is forced “off”.

C.) Repeat the test listed above for every output channel to be tested.

D.) Indicate that the tests for each I/O point passed by initialing next to each I/O representative from each required participant should initial (panel fabricator, engineer, owner)

14.) Analog Input Test:

A.) For each analog input in the Control Panel Schematic Drawings – one-by-one connect a 4-20ma source to the input terminals.

B.) Verify the surge suppressor is in the circuit and the test is going through it.

C.) Verify in the PLC program readings for 4, 8, 12, and 20ma injected into the terminals.

D.) Verify signal is displayed correctly in HMI graphics page.

E.) Indicate that the tests for each I/O point passed by initialing next to each I/O representative from each participant should initial (panel fabricator, integrator, 15.) Analog Output Test:

A.) For each analog output in the Control Panel Schematic Drawings, one-by-one connect a 4-20ma Signal Meter to the Output terminals.

B.) Verify the surge suppressor is in the circuit and the test is going through it.

C.) For each analog output point, enter the number in the PLC tag equal to the engineering unit zero. Verify that 4ma is present on the output terminals.

D.) For each analog output point, enter the number in the PLC tag equal to the engineering unit maximum. Verify that 20ma is present on the output terminals.

E.) Indicate that the tests for each I/O point passed by initialing next to each I/O representative from each required participant should initial (panel fabricator, , 16.) UPS test:

With power applied to the UPS input terminals, assure that the output circuit of the UPS will be loaded.

A.) The UPS status indicators should show that it is “OK” and indicate charge level of the internal batteries and the remaining power.

B.) Allow the internal system to charge the batteries fully.

C.) Observe the readout on the UPS for “length of time remaining” indicated (if applicable). It should meet or exceed the calculated time required to provide back-up power to the panel.

D.) Disconnect the UPS from the outlet and verify 110vAC on the load side of the UPS

Verify the UPS has been successfully tested

Functional Demonstration Tests

This test is primarily at the Owner’s or Engineer’s discretion as to what is desired to be tested.

Most importantly to maintain critical system stability, and thus important to test thoroughly, is the pump monitoring, control and sequencing specifically included below:

17.) Motor Control Test:

A.) From any HMI computer or from the local OIT, login with the appropriate level of security to have access to manual operation

B.) Set the PLC pump operation to Manual. From any HMI computer, initiate Start or Stop commands for each pump. Verify the start/stop operation of the appropriate pump’s starter.

C.) From any HMI, adjust the speed setpoints of the VFD pumps.

Verify that the appropriate VFD operates at the desired speed.

D.) Set the PLC pump operation to Manual. From the local OIT, initiate Start or Stop commands for each pump. Verify the start/stop operation of the appropriate pump’s starter.

E.) From the local OIT, adjust the speed setpoints of the VFD pumps.

Verify that the appropriate VFD operates at the desired speed.

F.) Verify failed to start or stop alarms and any associate alarms for Manual operation of each starter and VFD.

18.) Panel Component Test:

A.) Perform functional tests from the PLC program (as required) for all control panel components including but not limited to:

Horn Strobe Alarm silence button E-Stop button E-Stop reset button Start buttons Stop buttons Selector switches Panel intrusion switch Power loss relay All timer relays

19.) Discretionary Tests:

Perform Discretionary Tests per the Engineer or Owner

***** This concludes the Factory Acceptance Test *****

Review discrepancy sheets generated for this section of testing. If all discrepancies have been resolved, complete this testing form, file a logged copy, send a copy and all related information to the project manager for further distribution. Inform the project manager directly, that this stage of testing has been completed.

All points required of this test have been evaluated and this system is ready for the next stage of testing. The associated check-off sheet(s) and other documents have been reviewed and approved.

Panel Fabricator’s Designated Representative:

Signature Date

Engineer’s Designated Representative:

Owner’s Designated Representative:

Discrepancy Report Form

Discrepancy No:

Date: Required Resolution Date:

From:

To:

Discrepancy:

Resolution:

Resolution Approval

Signature: Date:

The issue listed above has been resolved and is completed

Signature: Date:

Copy this form for file records, 1 copy to each concerned party, including Engineer and send the original to the project manager. Verbally inform the project manager that this issue is closed.