FAT Procedure-FGI Kakinada Rev-1

Factory Acceptance Test Procedure

Revision Rev0 Rev 1 Rev 2 Title Client

Date 5/02/13 18/02/13 Factory Acceptance Tests

Procedure FGI

Prep By RK RK Project Prepared By

Chkd By PP PP CHS for 5th Berth Schneider Electric India Ltd.

FACTORY ACCEPTANCE TEST PROCEDURE

Project : PLC Based CHS for 5th Berth of KSPL

Customer : M/s. Felguera Gruas India

End user : Bothra Shipping Services

PO No. : 4510032995 Dated 29-Oct-12

SO No. : 1976909

Project Manager : Mr. Gokulakrishnan Sa

Date : Feb 5, 2013




Procedure FGI



CONTENTS

INTRODUCTION

GENERAL

FAT SCHEDULE

SECTION 1 : REVIEW OF DOCUMENTS & TEST EQUIPMENTS

1.1 REVIEW OF DOCUMENTS 1.2 REVIEW OF TEST EQUIPMENTS

SECTION 2 : SYSTEM HARDWARE

2.1 BOM VERIFICATION 2.2 DIMENSIONAL/ MECHANICAL INSPECTION 2.3 ELECTRICAL PROTECTION DEVICES INSPECTION 2.4 PANEL EARTHING TEST 2.5 PANEL GENERAL ARRANGEMENT & WIRING INSPECTION 2.6 SYSTEM ARCHITECTURE VERIFICATION

SECTION 3 : SYSTEM FUNCTIONING

3.1 PLC BOOT UP & RIO POWER ON 3.2 PLC COMMUNICATION PORTS 3.3 I/O FUNCTION CHECKs

DIGITAL INPUTS DIGITAL OUTPUTS ANALOG INPUTS RTD INPUTS

3.4 POWER SUPPLY UNIT (PSU) 24V DC TEST 3.5 RING REDUNDANCY TEST

SECTION 4 : PLC HARDWARE FUNCTIONING

4.1 PROCESSOR MEMORY RETENTION VERIFICATION

SECTION 5 : FAT CONCLUSION




Procedure FGI



INTRODUCTION, GENERAL & FAT SCHEDULE

INTRODUCTION

The Factory Acceptance test (FAT) is provided in accordance with Schneider India quality system & is in line with manufacturing quality plan. The Factory Acceptance test (FAT) is a procedure for inspection of each panel hardware and accessories.

GENERAL

1) Objectives:

The factory Acceptance Test is carried out in order to demonstrate that : o The system and its components function properly. o Manufacturing, assembly, configuration are done correctly. o System performance is in compliance with the approved functional

specification.

2) Records established during FAT:

Result of each test is recorded in observation section. Collective result of FAT will be recorded on FAT conclusion section.

FAT SCHEDULE

The Project Manager is responsible for the overall execution of the FAT and will be the prime interface between the client inspectors and the Schneider engineers from the beginning, to the completion of the FAT. Schneider shall give formal Inspection call inviting inspectors to witness the FAT.

The inspection call provides information on :

FAT start Date FAT Place Duration of FAT Internal test reports




Procedure FGI



SECTION 1 : REVIEW OF DOCUMENTS & TEST EQUIPMENTS

1.1 REVIEW OF DOCUMENTS

OBJECTIVE :

Verify correct approved documents are referred for the FAT.

PROCEDURE : Check that the Construction drawings have been established on the basis of the approved drawings transmitted at the time of inspection call. Check that the modifications carried by the Construction drawings are marked in blue pen and dated and signed by the engineer-in- charge. Check that the modifications carried in the drawings do not affect the design.

OBSERVATIONS:

1.2 REVIEW OF TEST EQUIPMENTS

OBJECTIVE : Check that all Test and measurement equipments to be used for inspection have a valid calibration status.

LIST OF TOOLS : Multimeters, Current source, Screw driver sets, RTD Simulator, Measurement Tape

OBSERVATIONS :




Procedure FGI



SECTION 2 : SYSTEM HARDWARE

2.1 BOM VERIFICATION OBJECTIVE : The purpose is to verify all offered components are

available as per approved BOM.

REFERENCE : Approved Bill of material, Approved Data sheets

CRITERIA : Offered system (hardware & software) are as per approved BOM.

OBSERVATIONS :

2.2 DIMENSIONAL / MECHANICAL INSPECTION OBJECTIVE : The purpose of this inspection is to verify that, Dimensions

of the PLC Panel is in line with approved GA drawing. The Panels are free from any mechanical damage.

REFERENCE : Approved GA drawing.

PROCEDURE : Visually check the dimensions of the panel as per approved drawings with measuring tape. Visually check that all panel are free from any deformity.

CRITERIA : Physical dimensions are as per the approved panel drawings.

OBSERVATIONS :




Procedure FGI



2.3 ELECTRICAL PROTECTION DEVICES INSPECTION OBJECTIVE : The purpose of this inspection is to verify rating of protection

devices as per approved power distribution drawing.

REFERENCE : Approved Panel power distribution drawing.

PROCEDURE : Compare the rated capacity of each protection device with approved panel power distribution drawing.

CRITERIA : Ratings of protection devices are as per the approved panel power distribution drawings.

OBSERVATIONS :

2.4 PANEL EARTHING TEST OBJECTIVE : The purpose of this test is to ensure the safety of the

Personnel and installed equipment from any electrical hazards / short circuits.

PROCEDURE : Check that the Electrical earth bus-bar is connected to Earth point of incoming supply. Check the panel

chassis is connected to the Electrical earth bus-bar. Check the continuity between Instrument earth and Electrical earth. Check the potential between neutral and Electrical earth bus-bar using Multimeter.

CRITERIA : Multimeter will not shows continuity between Instrument earth bus-bar and Electrical earth bus-bar

Potential between panel earth bar and neutral should be Less than 4V.

OBSERVATIONS :




Procedure FGI



2.5 PANEL GENERAL ARRANGEMENT & WIRING INSPECTION OBJECTIVE : The purpose of this inspection is to verify that, General

Arrangement (GA) & wiring of the panel is as per approved Internal Layout drawing, Power Distribution drawing and IO wiring diagram

REFERENCE : Approved Internal Layout drawing, Power Distribution drawing and IO wiring diagram

.

PROCEDURE : Visually check GA of panel and wire color & sizes as per Approved Internal Layout drawing and IO wiring diagram. Check for wiring continuity as per Power Distribution drawing

CRITERIA : GA of panel and wire color & sizes are as per Approved Internal Layout drawing and IO wiring diagram.

OBSERVATIONS :

2.6 SYSTEM ARCHITECTURE VERIFICATION OBJECTIVE : The purpose is to verify that, the offered System architecture conforms to the approved System

architecture .

REFERENCE : Approved System Architecture Diagram

PROCEDURE : Check the system components are integrated as per approved system architecture diagram.

EXCLUSION : Connection of Connexium Switches through LIU with FO cable. (Connection between Switches shall be through FO patch Cords)

CRITERIA : System architecture is integrated as per the approved System architecture diagram

OBSERVATIONS :




Procedure FGI



SECTION 3 : SYSTEM FUNCTIONING

3.1 PLC BOOT UP & RIO POWER ON OBJECTIVE : PLC goes to normal operation on powering up, provided

all configurations are stored in PLC.

PROCEDURE : Power ON the PLC system (CPU & RIO). Using Unity Pro, Build the configuration. Ensure Automatic start in RUN in CPU configuration is enabled and Download the same into the PLC. Check PLC is in RUN mode and all Modules Active LED are ON Power OFF the PLC and Power ON again

CRITERIA : On power cycling, the PLC displays Run mode automatically.

OBSERVATIONS :

3.2 PLC COMMUNICATION PORTS OBJECTIVE : Connection of the programming PC to the PLC

through programming connection ports (USB, Ethernet)

PROCEDURE : Connect the programming PC to programming connection port of CPU. Using Unity Pro configure communication protocol: Menu PLC Set Address PLC Media: USB, Address: SYS OK Connect to PLC : Menu PLC Connect Transfer Program to PLC : Menu PLC Transfer Project to PLC

CRITERIA : The PLC displays Run / Stop mode automatically after completion of program transfer.

OBSERVATIONS :




Procedure FGI



3.3 I/O FUNCTION CHECK

DIGITAL INPUTS

OBJECTIVE : The purpose of this test is to check the function of digital input module from DI Relay Board terminals.

REFERENCE : Approved IO wiring diagram.

PROCEDURE : Simulate the contact at DI Relay board terminal. Connect 24VDC from bus-bar 1BB to DI Relay board Field Interrogation terminal

Short the individual Relay board field terminal by using short-link. Check the corresponding DI status LED indication on PLC Input module and also observe the same in the Unity Pro Animation table.

CRITERIA : Individual DI LED indication on Input module should be ON.

OBSERVATIONS :

DIGITAL OUTPUTS

OBJECTIVE : The purpose of this test is to check the function of digital output module up to DO Relay Board terminals.


PROCEDURE : Force the Output using Unity Pro from programming PC. Observe LED Indication in the corresponding digital output module. Check Relay Operation and continuity of corresponding contacts at DO Relay board terminal.

CRITERIA : Individual DO LED indication on Output module should be ON.

OBSERVATIONS :




Procedure FGI



ANALOG INPUTS

OBJECTIVE : The purpose of this test is to check the function of analog input module from marshalling terminal.


PROCEDURE : Connect the source meter to the corresponding marshalling terminal . Simulate 4-20mA in various steps Observe the counts in the Unity Pro Animation table through programming PC.

CRITERIA : Correct AI counts for corresponding 4-20mA Inputs are Observed in Unity Pro

OBSERVATIONS :

RTD INPUTS

OBJECTIVE : The purpose of this test is to check the function of RTD Input module from marshalling terminal.

REFERENCE : Approved IO wiring diagram and RTD table

PROCEDURE : Connect variable resistor to the corresponding marshalling terminal . Simulate resistor in various steps Observe the value in the Unity Pro Animation table through programming PC.

CRITERIA : Correct RTD value for corresponding resistance Inputs are Observed in Unity Pro

OBSERVATIONS :




Procedure FGI



3.4 POWER SUPPLY UNIT (PSU) 24V DC TEST OBJECTIVE : The purpose of this test is to ensure that the control panel is

powered in normal conditions and the Bulk Power Supply delivers interrogation voltage

PROCEDURE : Measure the voltage of incoming power supplies Measure the Output voltage of Bulk Power Supply generated inside the panel. Check the Voltage in Bus Bars

CRITERIA : The Bulk Power Supply generating 24V DC inside the panel.

OBSERVATIONS :

3.5 RING REDUNDANCY TEST OBJECTIVE : The purpose of this test is to ensure that the Modbus TCP/IP & FO communication works in RING topology

PROCEDURE : Check the system components for Ring type communication are integrated as per approved system architecture diagram. Check for the Network Switch as per the specification

EXCLUSION : Connection of Connexium Switches through LIU with FO cable. (Connection between Switches shall be through FO patch Cords)

CRITERIA : Communication works in any direction (failure of one line) All network ports in Switch will be working

OBSERVATIONS :




Procedure FGI



SECTION 4 : PLC HARDWARE FUNCTIONING

4.1 PROCESSOR MEMORY RETENTION VERIFICATION

OBJECTIVE : Purpose of this verification is to check program retention (in PLC Processor) in case of power failure.

PROCEDURE : 1. Check the CPU battery is installed. 2. Download program to PLC. 3. Switch OFF the power supply of PLC rack and wait for 5 minutes. 4. Switch ON the power supply of PLC. 5. Check with programming PC that PLC has retained program.

CRITERIA : PLC retains the program

OBSERVATIONS :




Procedure FGI



SECTION 5 : FAT CONCLUSION

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Schneider Customer End user

FAT Procedure-FGI Kakinada Rev-1

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