Reference Doc 01055 XX DCS FAT Rev00A

Jazan Refinery and Marine Terminal
Project
EPC 13 UTILITY PACKAGE
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HWL DOC. NO.: 0105513DCS

FAT
DCS FACTORY ACCEPTANCE TEST PLAN
Vendor's Name
: Honeywell Turki Arabia Ltd.
COMPANY Name
: Aramco Overseas Company
Purchaser Name
: Hitachi, Ltd.
Plant Location
: Jazan, Saudi Arabia
Project Name
:Jazan Refinery and Marine Terminal Project
Purchase Order No.
: P-2171-001-A
Equipment/Material Name and Item and or Tag Number :

Document Title
: Power Requirements - MPS
Vendor's Document No. : 0105513DCSFAT

CONTRACT Number
JAZAN REFINERY AND MARINE TERMINAL PROJECT

ISSUE PURPOSE : First Issue
RESULT CODE
: A, B, C, R
NEXT STATUS
: FR, FA, FC, FN, AB
RESUBMISSION DATE :
RESPONSIBLE DEPT./PERSON :
REVIEW DATE :
A:Approved without Comment; B: Approved with Minor Comment

C:Not Approved; R: No Subject to Review
Approval or review hereunder shall not be construed to relieve Supplier/Subcontractor of his
responsibilities and liability under the Contract.
JOB No.
PO No.
Serial No.
HTC DOC. NO.
V-XXXX-XXX-X-XXXX
HTC Doc. No.
V-2171-001-A-0076
EQUIPMENT No.
Date
30-Jul-2013
DCS Factory Acceptance Test Plan Rev00 A
REV.
00A
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Internal Revision History

Rev.
Date
Description
Prepared
Checked
Approved
00A
13 July 2013
First Issue
VR
KM
MY
Issue Revision History

Rev.
Issue Date
Issue Purpose
From
Issue To
Approved
00A
13 July 2013
First Issue
Honeywell
HITACHI
HITACHI
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TABLE OF CONTENTS
1 INTRODUCTION.......................................................................................7
1.1 Project Overview...............................................................................7
1.2 Purpose.............................................................................................7
1.3 Reference Documents......................................................................8
1.3.1 Saudi Aramco Standards.............................................................8
1.3.2 Project Specification Document...................................................8
1.3.3 Honeywell Project Document.......................................................8
1.4 Abbreviations....................................................................................9
1.5 Safety requirements during the Pre-FAT and FAT..........................12
1.5.1 Safety of Test Personnel............................................................12
1.5.2 Electric Shock Hazard................................................................12
1.5.3 Trip Hazards...............................................................................13
1.5.4 Injury from Hand Tools...............................................................13
1.5.5 Noise..........................................................................................14
1.5.6 Care of Equipment.....................................................................14
2 Overview................................................................................................15
2.1 Hardware tests................................................................................15
2.2 Application software tests...............................................................15
2.3 System functionality tests...............................................................15
2.4 System reliability test......................................................................16
3 PRE-REQUISITE....................................................................................17
3.1 System Equipment..........................................................................17
3.2 Documentation................................................................................17
3.3 Inspection and Vendor Pre-FAT Testing..........................................18
3.4 Test Equipment...............................................................................18
3.5 Other Prerequisites.........................................................................19
4 PERSONNEL REQUIREMENTS............................................................19
4.1 PCS Vendor Responsibilities.........................................................19
4.2 PCS Vendor Personnel:..................................................................19
4.3 CONTRACTOR Responsibilities.....................................................20
4.4 CLIENT Responsibilities.................................................................20
5 CONFIGURATION..................................................................................21
5.1 Management / Control....................................................................21
5.2 System Configuration......................................................................21
5.3 Test Configuration...........................................................................22
5.4 Simulation.......................................................................................22
5.5 Factory Untestable Items................................................................22
5.6 Test Database.................................................................................23
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6 Testing....................................................................................................23
6.1 Structured Testing...........................................................................23
6.1.1 Test plan.....................................................................................23
6.1.2 Test schedule.............................................................................24
7 Mandatory Functional Tests................................................................26
7.1 Non-Fieldbus Tests.........................................................................26
7.2 Foundation Fieldbus Tests..............................................................27
7.2.1 Control Strategy Verification......................................................27
7.3 Unstructured Testing.......................................................................28
7.4 Reliability Test.................................................................................28
7.5 Retest Method.................................................................................28
8 TEST DOCUMENTATION.....................................................................29
8.1 Test Log...........................................................................................29
8.2 Test Result......................................................................................29
8.3 Test Discrepancies..........................................................................29
9 PROBLEM RESOLUTION.....................................................................30
9.1 Resolution During FAT....................................................................30
9.2 FAT Suspension / Resumption / Restart.........................................30
10 FACTORY ACCEPTANCE TEST REPORT...........................................31
1 FAT CERTIFICATE (PIB XX).................................................................32
12 APPENDIX 01 PROJECT SPECIFICATIONS....................................33
13 APPENDIX 03 TEST forms and record.............................................34
13.1 Physical Inspection of Cabinets, Operator Stations.......................34
13.1.1Operator Stations Check............................................................34
13.1.2System Cabinets Check.............................................................35
13.1.3Server Cabinets Check..............................................................36
13.1.4Network Cabinets Check...........................................................37
13.1.5FFPS System & Marshalling Cabinets Check...........................38
13.1.6DCS Marshalling Cabinets Check.............................................39
13.2 Servers and Stations Check...........................................................40
13.2.1Server Hardware Check DMZ-AVWS-01................................40
13.2.2Station Hardware Check .........................................................41
13.2.3Software Check .......................................................................42
13.3 Enterprise Model Check ...............................................................43
13.4 Server Configuration Check .........................................................44
13.5 Console & Flex Station Configuration Check..................................45
13.5.1Console / Flex Station NAME.................................................45
13.6 Printer Configuration Check............................................................46
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13.6.1Printer - NAME...........................................................................46
13.7 Experion Nodes Check...................................................................47
13.7.1Server Redundancy Check - NAME..........................................47
13.7.2Upgrade of System Software Check - NAME............................49
13.8 Network Check................................................................................50
13.8.1Network Nodes Check...............................................................50
13.8.2FTE Redundancy Check............................................................51
13.8.3FTE Switch Redundancy Check - NAME..................................52
13.9 C300 Controller Nodes Check........................................................53
13.9.1Controller - NAME......................................................................53
13.10 C300 Controller Loop Check......................................................60
13.10.1 Analog Input..........................................................................60
13.10.2 Analog Output.......................................................................61
13.10.3 Digital Input...........................................................................62
13.10.4 Digital Output........................................................................63
13.11 C300 Point Configuration Check................................................64
13.12 C300 Control Loops Configuration Check..................................65
13.13 C300 Logic Configuration Check...............................................66
13.14 C300 Sequence Logic Configuration Check..............................67
13.15 HMI Display Check.....................................................................68
13.16 Safeview Check..........................................................................69
13.17 EPKS Security Check.................................................................70
13.18 EPKS Diagnostic Check.............................................................71
13.19 FIELD BUS ENGINEERING TESTS..........................................72
13.19.1 FF Configuration Offline Checks...........................................72
13.20 FF Configuration Online Check..................................................73
13.20.1 FF Segment Check...............................................................74
13.20.2 FIM Redundancy Test - NAME.............................................75
13.20.3 FF Bulk Power Supply Redundancy Check..........................76
13.20.4 FF Power Conditioner Module Redundancy Check.............77
13.21 ESD(SM) Communication Check...............................................78
13.21.1 SM -.......................................................................................78
13.21.2 Quick Builder Database Check.............................................80
14 APPENDIX 04 C300 LOOP CHECK record.......................................81
15 APPENDIX 05 C300 POINT CONFIGURATION check record.........82
16 APPENDIX 06 C300 LOGIC CONFIGURATION check record........83
17 APPENDIX 07 C300 SCM CONFIGURATION check record............84
18 APPENDIX 08 hmi DISPLAY CHECK record....................................85
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19 APPENDIX 09 FF CONFIGURATION CHECK record.......................86

20 APPENDIX 10 FF SEGMENT CHECK record...................................87
21 APPENDIX 11 Quick builder DATABASE CHECK record...............88
2 APPENDIX 12 deficiency log.............................................................89
23 APPENDIX 12 System log.................................................................90
24 APPENDIX 04 Deficiency Log............................................................91
25 APPENDIX 05 - Applicable System Standards...................................92
26 APPENDIX 06 Project Specification.................................................94
1
1.1
INTRODUCTION
Project Overview
Saudi Aramco intends to construct a 400 MBD grassroots refinery and hydrocarbon terminal facilities
within Jazan Economic City (JEC), Saudi Arabia located in south-west on the Red Sea coast. The

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strategic location of the refinery within JEC will leverage the existing distribution assets for products
transfers to the demand centers in the area.
Jazan Refinery will be a semi-conversion refinery that processes 400 MBD of crude oil of either
100% Arabian Medium crude or a mixture of 50/50 AM/Arabian Heavy crudes which will be supplied
from Saudi Aramcos AH and AM crude supply systems on the Eastern province.
In addition, the refinery will upgrade 45 MBD of Jeddah Refinery intermediate feed stocks (Naphtha,
Distillate, and Vacuum Gas Oil) to high quality finished products.
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 Honeywell scope of
work for CCR & PIB-053 (EPC13 -HITACHI) for Jazan Refinery and Marine Terminal Project.
This Document is prepared based on guideline provided in the SAEP-1634. 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.

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1.3.1
1.3.2
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Reference Documents
Saudi Aramco Standards

Document Number
Document Title
23-SAMSS-010
Distributed Control Systems
SABP-Z-002C
Functional Specification for Distributed Control Systems

(DCS)
34-SAMSS-820
Instruments Control Cabinets - Indoor
34-SAMSS-821
Instrument Control Panel Outdoors
SAES-Z-001
Process Control system Engineering standard
SAEP-1634
Factory Acceptance Test
Project Specification Document

Document Number
Document Name
J95-J-VE-536031
DCS Specification
J95-J-VE-536021
PCS Scope Of Work
J95-J-VE-536003
PCS Specification
J95-J-VE-536011
MAC Vendor Services
Honeywell Project Document

Document Number
Document Name
01055-XX-DCS-DLD
Panel Detailed Layout Diagrams (DCS)
01055-XX-DCS-BOM
Bill Of Material (DCS)
01055-XX-PCS-SDD
System Design Document (PCS)
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1.4
Abbreviations
Abbreviations
AC
AI
ANSI
AO
APC
API
ARC
ASCII
ASM
BMS
CCB
CCR
CCS
CCTV
CDR
CM
CMS
CPU
CRMS
DAHS
DC
DCS
DD
DFS
DI
DMR
DO
DSA
ECC
EPC
ES-C
ESD
ES-F
ESV
ETP
EWS
FAT
FDM
FEED
FF
FFPS
FIM
Description
Alternating current
Analog Input
American National Standards Institute
Analog Output
Advanced Process Control
American Petroleum Institute
Advanced Regulatory Control
American Standard Code for Information Interchange.
Abnormal Situation Management
Burner Management System
Central Control Building
Central Control Room
Compressor Control System
Closed Circuit Television
Critical Design Review
Control Modules
Condition Monitoring System
Central Processing Unit
Corrosion Monitoring system
Data Acquisition and Historization System
Direct current
Distributed Control System
Device Description
Detailed Functional Specifications
Digital Input
Dual Modular Redundancy
Digital Output
Distributed Server Architecture
Emergency Control Center
Engineering, Procurement and Construction
Experion Console Station
Emergency Shutdown (System)
Experion Flex Station
Experion Server
External Termination Panel
Engineering Workstation
Field Device Manager
Front End Engineering Design
Foundation Fieldbus
FOUNDATION Fieldbus Power Supply
Fieldbus Interface Module
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FAT
FO
FOPP
FTE
HIST
HMI
HVAC
HWL
I/O
IAMS
IEEE
IFAT
JB
LAN
LAS
LIMS
MC
MCC
MCC
MFACP
MIS
MOV
MPS
MTBF
MTS
MTTF
MTTR
N/A
NMR
OPC
OTS
OWS
P&ID
PAN
PAT
PCN
PCS
PDR
PFD
PIB
PID
PI
PV
QA/QC
QMR
RAID
RTD
RTU
Fiber Optic
Fiber Optic Patch Panel
Fault Tolerant Ethernet
Host Interoperability Supporting Testing
Human-Machine Interface
Heating, Ventilating and Air Conditioning
Honeywell
Input/Output
Instrument Asset Management System
Institute of Electrical and Electronics Engineers
Integrated Factory Acceptance Test
Junction Box
Local Area Network
Link Active Scheduler
Laboratory Information Management System
Marshalling Cabinet
Mechanical Completion Certificate
Motor Control Center
Main Fire Alarm Control Panel
Management Information System
Motor Operated Valve
Machinery Protection System
Mean Time Between Failures
Maintenance Training System
Mean Time to Failure
Mean Time to Repair
Not Applicable
Non Material Requirement
OLE for Process Control
Operator Training System
Operator Workstation
Piping and Instrument Diagram
Process Automation Network
Performance Acceptance Test
Process Control Network
Process Control System
Preliminary Design Review
Process Flow Diagram
Process Interface Building
Proportional Integral Derivative
Plant Information (System)
Process Variable
Quality Assurance/Quality Control
Quadruple Modular Redundant
Redundant Array of Independent Discs
Resistance Temperature Detector
Remote Terminal Unit
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SAEP
SAES
SAMA
SAMSS
SAN
SAT
SCADA
SER
SOE
SP
SRR
SAUDI ARAMCO Engineering Procedure

SAUDI ARAMCO Engineering Standard
Scientific Apparatus Manufacturers Association
SAUDI ARAMCO Materials System Specification
Storage Area Network
Site Acceptance Test
Supervisory Control and Data Acquisition System
Sequence of Events Recorder
Sequence of Event
Setpoint
System Readiness Review
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Safety requirements during the Pre-FAT and FAT

Testing will be carried out in accordance with:
1.5.1
Honeywell internal procedures.
FAT Procedure (this document).
Safety of Test Personnel
The main hazards present during test staging are:
1.5.2
Electric shock hazard / voltage hazards.
Trip hazards (untidy cables or work area).
Injury from hand tools.
The following hazards may be present:
Noise which may be in excess of what exists in an office environment.
Electric Shock Hazard
The main voltages used with the staged equipment are 240/110VAC and 24VDC. VAC presents a risk
of electric shock if care is not taken. The paragraphs below describe steps to manage the risk of
electric shock.
All personnel should be made clearly aware of AC voltage wiring/cabling.
Competent, qualified, licensed electrician will perform all AC voltage wiring/cabling.
Before working on AC Voltage Circuits:
Ensure the equipment is electrically isolated e.g. unplug the power lead from the outlet; or
switch the circuit breaker to the OFF position. Place electrical danger tags as necessary.
Using a multi-meter, always test for zero voltage before working on AC Voltage circuits.
Ensure that the multi-meter is calibrated and the test leads are in a satisfactory condition. It is
good practice to first check the multi-meter by testing for voltage at a known voltage source
(e.g. general power outlet).
Before energizing circuits 240VAC, 110VAC or 24VDC Circuits:
Confirm that no personnel are working on the circuit.
Confirm danger tags are on the isolation points.

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Confirm that the circuit has been wired and tested by a licensed electrician.
Ensure that all temporary wiring is safe.
Ensure Perspex covers are in place over live AC terminals, conductors and bus bars.
Ensure the cabinet(s) is properly earthed.
24VDC presents less of a danger than 240VAC, but personnel should be aware that the bulk
24VDC power supply can provide a high current. As with 240VAC, all test personnel should
take care not to short circuit any wiring. Metal wristwatches or jewellery should not be worn
when working in live panels.
Trip Hazards
Keep the work area clean and tidy;
Ensure that all cables are installed relatively neatly and away from walkways. Securely fasten
cables with cable-ties or floor tape as necessary;
All rubbish and old packaging should be kept out of the way or discarded if not required;
Maintain good house-keeping practice throughout.
Injury from Hand Tools
To avoid injury from hand tools, only use tools that are in a satisfactory condition. Always use
the correct tool for the job. If the task appears too difficult, or too much force is required, then
almost certainly there is a more suitable tool available.
Ensure electrical tools are within inspection period.
Noise
During testing, normal shop activity may cause noise which exceeds the levels found in a normal
office environment. Normal staging is in areas which are separated from noise producing activities.
In the event that unplanned machining activities are required in the area of testing and the noise levels
and duration are expected to exceed OSHA or other applicable guidelines, the activity will be
performed during times when the testing personnel are not present. If this activity is required during
the testing, the personnel will be informed of the activity and its duration and personnel may vacate
the area or use ear protection.
Ear plugs will be available for use during testing.
1.5.6
Care of Equipment

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Ensure that all system hardware and test equipment is treated with care. Do not allow cuttings
of wire or swarf from drilling to fall into any electrical equipment where it may cause short
circuits.
Check the required supply voltage on equipment labels before connecting the power. Take care
not to connect the wrong voltage e.g. 240VAC instead of 24VDC.
Drinks/fluids of any kinds are not allowed.
Take care not to knock/bump hardware/wiring connections when moving around in the
cabinet.
Use personal static earthing when handling any of the DCS modules.
Do not use mobile phones or radios inside the DCS System cabinet when the system is online.

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Overview
Factory Acceptance Test (FAT) consists of the following phases.
2.1
2.2
2.3
Hardware tests
Hardware verification and visual inspection.
Earthing and Power up checks.
DCS hardwired IO point test (IO allocation, EU and Transmitter ranges).
Cabinet alarm test.
Loop test for 100% IOs.
Application software tests
Verification of the network configuration
Point Database
Control Schemes
Logic Tests
Graphics Displays & Display Navigation
Offline Configuration Database Checks
System functionality tests
Power supply redundancy checks.
IO Module redundancy check
Development system communication (DCS to engineering work station) redundancy checks.
DCS to SM Communication checks.
PCDI communication redundancy checks.
Spare capacity verification.

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System reliability test
Checks continuous operation of the system for predefined time period without having any
failures in the system.

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PRE-REQUISITE
3.1
System Equipment
The following equipment will be tested during FAT.
3.2
Experion Servers
Experion consoles
Printers
Server cabinets
Network cabinets
C300 System cabinets
Connected System cables
Operator and Engineering workstations
Marshalling cabinets
FFPS System & Marshalling cabinets
Documentation
The FAT will be conducted based on the following documents.
Approved NMR602 Documents
Logic Drawings
Control Schemes
P&IDs
Cause & Effect
Alarm & Trip Setting
Instrument Loop Diagram
Logic Narrative
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Inspection and Vendor Pre-FAT Testing
PCS 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 DCS cabinets will
be installed with earth/grounding and communication cables, 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. PCS 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.
Honeywell DCS Systems will be verified as being ready for formal testing (FAT) as a requirement
of the SRR. After inspection and successful completion of SRR, system will be ready for FAT.
As-Built System at the completion of the System Readiness Review. The FAT shall not
begin until this documentation has been updated.
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
4-20 ma DC current source
Continuity Tester
Simulation Panel with Lamps, Switches and

Potentiometer

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Other Prerequisites
CONTRACTOR shall arrange Foundation Fieldbus devices one of each type for device
communication and Functional testing.
CONTRACTOR shall arrange FF Junction box and Terminator.
PCS Vendor will arrange Type A cable for Testing.
All DCS equipment will be fully assembled and powered-up during pre-FAT. DCS equipment will
be powered-up for 72 hours before FAT.
PERSONNEL REQUIREMENTS
4.1
PCS Vendor Responsibilities
PCS Vendor will provide the personnel, documentation and approved test equipment to conduct
the Factory Acceptance Test. Technical personnel from 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.
4.2
PCS Vendor Personnel:
Project Manager: Project Management

Technical Manager: FAT Management
FAT Lead: Package FAT Lead Engineering
Factory Lead: Lead Hardware installation activities and testing
Test Technician: Electrical, wiring and Loop Checking

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CONTRACTOR Responsibilities
CONTRACTOR will provide their representative familiar with design inputs and the plant
operations. The personnel made available must be authorized to sign acceptance at each stage
of testing.
CONTRACTOR Personnel:
Responsible Test Witness Leader
Responsible Test Witness Engineers
4.4
CLIENT Responsibilities
CLIENT will provide sufficient personnel familiar with the plant operations, Honeywell systems
and Instrumentation to witness tests performed by PCS Vendor in accordance with approved test
procedures.
The personnel made available must be authorized to sign acceptance at each stage of testing.
CLIENT Personnel:
Responsible Test Witness Leader
Responsible Test Witness Engineers

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CONFIGURATION
5.1
Management / Control
The FAT will be conducted as per approved FAT procedure. Each action will be performed as
indicated in the test procedure. Result 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
Following system will be tested for complete Hardware and Software functionality.
C300 Controller: - It is redundant DCS controller. It will be installed in the DCS system cabinet.
Controller configuration and redundancy will be verified.
EPKS Server: - EPKS server is redundant server installed in the Server cabinet located in the
PIB. Server configuration and redundancy will be verified.
System Cabinet: - System cabinet will host C300 controller, FIM, PGM module and Series C IO
module.
Marshalling Cabinet - Field cable will be terminated in the Marshaling Cabinet.
FFPS Marshalling Cabinet: -Bulk power supply required for Foundation Fieldbus system will be
mounted in FF power supply cabinet.
Server Cabinet: - Rack mounted redundant Experion server will be installed in Experion server
with KVM switch.
Network Cabinet: - Network component like FTE switch, converter will be installed in the Network
Cabinet.
DCS Operator Console: - DCS operator station will be installed in the DCS operator console.

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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.
Following items will be included:
Hardware/Software Configuration deviation
Operational and performance deviations
Reason for each deviation and affected requirements
5.4
Simulation
Conventional I/Os
Since entire set of actual field devices cannot be connected and used for process simulation during
FAT, simulation equipment will be used for all Hardwired IOs.
Loop Testing All I/Os will be tested using following simulation equipment.
AI simulation 4-20 mA generator
DI simulation Jumper
DO simulation Lamp
AO simulation Multi-Meter
Logic testing During logic testing inputs (DI and AI) will be simulated from the hardwired input simulation panels
and DOs will be wired to lamp panels or LED panels.
FF I/Os
Since it is not possible to have all FF devices, FF JBs and cables at the FAT floor, the control
strategy related to FF will be checked by using simulation software.
5.5
Factory Untestable Items
The Integration of third party equipment with DCS will not be tested in FAT. In FAT PC based
simulator will be used to simulate third party System. The actual communication with third party
system will be checked during IFAT.

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Test Database
The FAT will be conducted with latest approved database from the Contractor.
For any database, change during FAT will be documented in sufficient detail. The effect of each
deviation and requirements on system performance will be studied and described in detail. This
includes replacement / addition / deletion of tags / tag parameters.
6
Testing
The system equipment to be tested during FAT comprises of all hardware and software as per the DCS
BOM (Bill of Material) document and approved configuration design from contractor.
The equipment will be staged and integrated in accordance with the approved system architecture
requirements.
6.1
Structured Testing
Various aspects of structured testing are elaborated below:
6.1.1 Test plan

The structured testing will be conducted as per test forms given in Appendix A.

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6.1.2 Test schedule

The FAT will be conducted as per dates mentioned in Project Master Schedule.
The daily FAT schedule will be as below.
8.00 To 8.30 AM
8.30 To 12.00 PM
12.00 To 1.00 PM
1.00 To 5.00 PM
5.00 To 5.30 PM
Daily activity review

Testing
Lunch
Testing
Progress Review for the day
Detailed daily schedule

The detailed day wise schedule will be provided at the time of FAT.
Week
Schedule
Description Of Activity
Day 1
Day 2
Week 1
Day 3
Day 4
Day 5
Week 2
Day 6
Day 7
Day 8
Day 9
Day 10
Day 11
Day 12
Week 3
Day 13
Day 14
Week 4
Day 15
Day 16
Day 17
Day 18
Day 19
Day 20
Week 5
Day 21
Day 22
Day 23
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Week
Week 6
Schedule
Day 24
Description Of Activity
Day 25
Day 26
Day 27
Day 28
Day 29
Day 30
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Mandatory Functional Tests

7.1
Non-Fieldbus Tests
The following will be the mandatory test during FAT.
Redundancy and fault tolerance Test

EPKS Server
C300 Controller
IO Module
Communication link Check
Replacement Test
IO Module
Upgrade of Software
EPKS Server
Analog Output Failure test
Invalid value propagation test
Loop Test
System Performance Test
Security Test
Spare Capacity
C300 Controller
IO Module
Diagnostic Check
Controller loading Check
Visual Inspection
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Foundation Fieldbus Tests
The following are mandatory tests for Fieldbus portion of the system. Since Input and Output
functions are resident in the functions blocks inside fieldbus devices; integrating all the fieldbus
segments with the Fieldbus control unit and wiring at Factory Acceptance Test will not be
possible. Not all Fieldbus Devices and FF field cables will be available during FAT. In practice, it
is difficult to gather all devices and components at one place for Factory Acceptance Tests due to
various constraints.
Following tests will be carried on Sample FF Segment.
Redundancy or fault tolerance
Alarm and message for fieldbus
Verify that system register the fieldbus device using plug and play function (Plug & play
means unique address assignment to each fieldbus on the segment by H1 card. This test will
be performed to validate automatic address assignment to the device on segment, in case of
duplicate address. Device commissioning & loading will be performed manually)
Interoperability (CONTRACTOR shall provide one device of each type of Interoperability

test)
Loop check Loop check will be done using one sample test device. This device will be
assigned to each segment to check the loop. RTD Simulation will be included in Test
Equipment.
7.2.1 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.
Refer to test form 13.12

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Unstructured Testing
Any unstructured test / any test outside the approved FAT procedure will be conducted after FAT
conclusion. After completion of structured testing, a 5 days period will be reserved for
unstructured testing. The effect of unstructured test on system performance will be studied and
discussed before performing any such test.
7.4
Reliability Test
It is the test for continuous operation of the system over a significant period without failure,
indicating the availability of the system in all situations.
For Pre-FAT the system will be fully installed with all configuration loaded and all IOs connected
with simulation panel. The pre-FAT check will be done on the system and test record will be
generated.
After Pre-FAT the customer will perform the FAT/IFAT on the same system. Thus, the system will
be continuously tested as per different tests procedure of FAT and IFAT.
7.5
Retest Method
Any discrepancy found during testing, will be corrected by PCS Vendor Engineer. The retest will
be conducted as per FAT procedure.

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TEST DOCUMENTATION
8.1
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 step and unsuccessful test will be
marked as NOT OK. If the result does not correspond to the expected result, the FAT Test
Sheets will be marked as Not OK and an entry will be made in the Deficiency log sheet.
8.2
Test Result
At the end of FAT, the hardcopy of Deficiency Logs & Test Sheets will be generated as a FAT
record. All test results / records will be signed by PCS Vendor, CONTRACTOR and CLIENT
representatives. One set will be copied to CONTRACTOR.
8.3
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.

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PROBLEM RESOLUTION
9.1
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 PCS Vendor, PCS Vendor engineer will rectify the fault. Status will be
updated to CLIENT / CONTRACTOR to enable them to repeat the test. Acceptance of deficiency
rectification will be signed by CONTRACTOR / CLIENT and PCS Vendor authorized
representatives. If the above mentioned re-test fails, then this test will be rescheduled at the 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 CONTRACTOR / CLIENT, it will be
recorded in the log sheet as Not in Scope. If PCS 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 FAT, or completed on site
9.2
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.
.

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10 FACTORY ACCEPTANCE TEST REPORT

Upon successful completion of all tests, CLIENT, CONTRACTOR and PCS 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 FAT.
The following records will be generated during the FAT:
FAT Certificate
Deficiency Log
Test Sheets
Final FAT meeting MOM
Copy of mark-ups.

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11 FAT CERTIFICATE (PIB XX)
Honeywell Middle East

FACTORY ACCEPTANCE TEST CERTIFICATE
(PIB XX)
THE UNDERSIGNED HAS INSPECTED AND TESTED THE SYSTEM TO
PCS VENDOR DOCUMENT NO.
AND ACCEPTS THAT THE DCS SYSTEM MANUFACTURED FOR
SAUDI ARAMCO JAZAN PROJECT (ARAMCO PROJECT NO. BI-10-01055)
HAS BEEN BUILT TO THE AGREED SPECIFICATIONS, VARIATIONS
AND
ATTACHED LISTED EXCEPTIONS AND MEETS THE REQUIREMENTS
OF
CONTRACTOR P.O NO.
FAT LOCATION : Honeywell DTV
Start Date
End Date
--------------
For Aramco
CLIENT
For XXX
CONTRACTOR
For Honeywell
PCS Vendor
Title:
Title:
Title:
Date:
Date:
Date:
------------

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12 APPENDIX 01 PROJECT SPECIFICATIONS

The design of system is based on bellow project specifications.
Sr. No
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Description
Automation Design Criteria
Emergency Shutdown System
Process Control System Overview
Process Control System Integration
PCS Configuration Guidelines
Control and Marshalling Cabinets Specification in
Fieldbus Foundation Specification
Hart Specification
Smart Valve Monitoring System SVMS
Smart Shutdown Valve Monitoring System SZVMS
Alarm Management System
Data Acquisition & Historization System
Instrument Asset Management
Fire Detection System
Gas Detection System
PCS System Design Document
Emergency Notification Alarm System
Instrument Block Diagram Emergency Notification Alarm
Operator Console CCR Area 1
CCR ENG/MAN Console
Typical PIB Maintenance Console
DCC Console
Emergency Communication Console CCR
Maintenance Training Console
Control and Instrumentation Philosophy
Automation Scope Of Supply SRU, Utilities and offsite
PCS I/O Summary WUC Scope
Process Control System Vendor Services
Operator Training Simulator
Condition and Vibration Monitoring System (CMS/VMS/FFVMS)
Inspection and Testing of Electronics Systems
Compressor Control System (CCS)
CCR Layout
Document No
PP-118009
PP-118158
PP-118159
PP-118160
PP-118161
PP-118163
PP-118164
PP-118167
PP-118168
PP-118169
PP-118170
PP-118171
PP-118172
PP-118173
PP-118174
PP-118175
PP-118180
PP-118181
PP-118228
PP-118231
PP-118281
PP-118282
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118394
PP-418002
PP-118390
PP-118162
PP-118166
PP-118176
PP-118151
PP-118178
PP-111011
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Description
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Document No
PP-118900
Control Room Layout
13 APPENDIX 03 TEST forms and record

13.1 Physical Inspection of Cabinets, Operator Stations
13.1.1 Operator Stations Check

13.1.1.1
Operator Station NAME

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify and document that all the Hardware are
installed.
Hardware and Approved drawings issued for construction shall be available
Console Drawings - NMR602.5 & 6
Test Procedure
No.
Test#
1.1
Detail Test Item
1.4
1.5
Verify Console design is as per approved Console

Diagram
Verify Console Exterior free of significant
marks/scratches
Verify proper open and closing of doors and
handle locks
Verify all components are correctly labelled
Confirm Ground bars are installed as required
1.6
Verify bill of material (BOM)
1.2
1.3
Check the distribution of System Power (120V

AC).
Purpose: Overall acceptance of this module by Customer
TEST Result
OK
NOK
RTST OK
1.7
BY:
DATE:
SIGNATURE:

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13.1.2 System Cabinets Check

13.1.2.1
System Cabinet NAME

NAME
Purpose
Pre-requisite
Reference Document
installed
System Cabinet Drawings - NMR602.5 & 6
Test Procedure
No.
Test#
1.1
1.2
1.3
1.4
1.5
Detail Test Item
TEST Result
OK
NOK
RTST OK
Verify cabinet Hardware and design is as per

approved Cabinet Drawings
Verify Cabinet Exterior free of significant
marks/scratches
Verify proper open and closing of doors and
handle locks
Verify cabinet and all components are correctly
labelled
1.6
Verify circuit breakers and power wiring is as

required
1.7
Verify ground bars are installed as required
1.8
Verify dust filters, Fan, RTD, Smoke detector

and lighting assembly are as per document
1.9
Check the distribution of System Power (120V

AC) and 24V DC Power
BY:
DATE:
SIGNATURE:

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13.1.3 Server Cabinets Check

13.1.3.1
Server Cabinet NAME

NAME
Purpose
Pre-requisite
Reference Document
installed
Server Cabinet Drawings - NMR602.5 & 6
Test Procedure
No.
Test#
1.1
1.2
1.3
1.4
1.5
Detail Test Item
TEST Result
OK
NOK
RTST OK
Verify cabinet Hardware and design is as per

approved Cabinet Drawings
marks/scratches
Verify proper open and closing of doors and handle
locks
Verify cabinet and all components are correctly
labelled
1.6
Verify circuit breakers and power wiring is as

required
1.7
1.8
Verify RTD, Smoke detector and lighting assembly

are as per document
1.9
Verify KVM Switch
1.10
Check the distribution of System Power (120V AC)
BY:
DATE:
SIGNATURE:

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13.1.4 Network Cabinets Check

13.1.4.1
Network Cabinet NAME

NAME
Purpose
Pre-requisite
Reference Document
installed
Network Cabinet Drawings - NMR602.5 & 6
Test Procedure
No.
Test#
1.1
1.2
1.3
1.4
1.5
Detail Test Item
OK
NOK
RTST OK
Verify cabinet Hardware and design is as

per approved Cabinet Drawings
marks/scratches
Verify proper open and closing of doors
and handle locks
Verify cabinet and all components are
correctly labelled
1.6
Verify circuit breakers and power wiring is

as required
1.7
1.8
Verify dust filters, Fan, RTD, Smoke

detector and lighting assembly are as per
document
Check the distribution of System Power
(120V AC)
1.9
TEST Result
BY:
DATE:
SIGNATURE:
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13.1.5 FFPS System & Marshalling Cabinets Check

13.1.5.1
FFPS System & Marshalling Cabinet - NAME

NAME
Purpose
Pre-requisite
Reference Document
installed
FFPS Cabinet Drawings - NMR602.5 & 6
Test Procedure
No.
Test#
1.1
1.2
1.3
1.4
1.5
Detail Test Item
OK
NOK
RTST OK

marks/scratches
and handle locks
correctly labelled
1.6
Verify circuit breakers and power wiring is

as required
1.7
1.8
Verify dust filters, Fan, RTD, Smoke

detector and lighting assembly are as per
document
(120V AC) and 24V DC Power
1.9
TEST Result
BY:
DATE:
SIGNATURE:
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13.1.6 DCS Marshalling Cabinets Check

13.1.6.1
DCS Marshalling Cabinet NAME

NAME
Purpose
installed
Pre-requisite
Reference Document
Marshalling Cabinet Drawings - NMR602.5 & 6
Test Procedure
TEST Result
No.
1
Test#
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Detail Test Item

OK
NOK
RTST OK

marks/scratches
and handle locks
correctly labelled
Verify that cable bundles in ducts are
flexible and sufficient space for future
expansion is available
Confirm circuit breakers and power wiring
is as required
1.8
Confirm ground bars are installed as

required
1.9
Confirm dust filters and lighting assembly

are as per document
1.10

(120V AC) and 24V DC Power
BY:
DATE:
SIGNATURE:
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13.2 Servers and Stations Check
13.2.1 Server Hardware Check DMZ-AVWS-01

NAME
Purpose
The purpose of this test is to verify and document that all the Server / Work
station PC Hardware are installed, configured and working properly
Windows 2008 Server Operating System must be loaded for the Servers and
Win 7 Operating System must be loaded on all the Work station PCs
Pre-requisite
Reference Document
Test Procedure
Required
No.
Test#
Detail Test Item
1.1
Verify Manufacture , Model no
(DELL R710)
1.2
Verify Hard disk Capacity and

specifications
438 GB
1.3
1.4
1.5
Verify RAM details

Verify presence of DVD Drive
Verify operating system
4 GB
OK
NOK
RTST
OK
Windows 2008
BY:
DATE:
TEST Result
SIGNATURE:

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13.2.2 Station Hardware Check

NAME
Purpose
The purpose of this test is to verify and document that all the Server / Work
station PC Hardware are installed, configured and working properly
Pre-requisite
Reference Document
Test Procedure
Required
No.
Test#
Detail Test Item
1.1
Verify Manufacture , Model no
(DELL T3500)
1.2
Verify Hard disk Capacity and

specifications
320 GB
1.3
1.4
1.5
Verify RAM details

Verify presence of DVD Drive
Verify operating system
4 GB
OK
NOK
RTST
OK
Win 7
BY:
DATE:
TEST Result
SIGNATURE:

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13.2.3 Software Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify and document that the Experion Software is
installed and configured on servers and stations as specified and working
properly.
Experion PKS software must be loaded.
Server must be ON and log on as administrator
Software License Certificate
Test Procedure
No.
Test#
1.1
Detail Test Item
From System Menu, go to System Configuration->

General -> Server License Details.
Verify System number against Software License
Certificate
1.2
Call up sysstartuppage.htm on the station and
verify Honeywell Experion PKS software version.
Verify that all stations are running with same version
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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13.3 Enterprise Model Check

NAME
Purpose
Pre-requisite
Reference Document
No.
Test#
1.1
2
2.1
2.2
3
The purpose of this test is to verify the Enterprise Model for the project.
Server must be On
NMR602.17: System Architecture Dwg
NMR602.2: Asset Configuration
Network Design Document
Test Procedure
FAT TEST
Detail Test Item
OK
NOK
RTST OK
From the Engineering Workstation, login with an

ENG level account, open Configuration Studio and
verify that a client connection can be established (a
login) to the EMDB system to be tested.
(From "Other targets Tab", Select Target Type =
EPKS System and target Name Field = <Server
Name>).
Enterprise Servers
Verify System name as defined in NMR602.11.
Verify the system contains Servers as defined in
NMR602.11.
3.1
Asset Model
From Configuration Studio, open the Asset Builder
and verify that the Asset tree is configured as defined
in the section 3.1 of NMR602.2: Attachment#06 Asset Configuration.
BY:
DATE:
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13.4 Server Configuration Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify the configuration of server.

Server must be On
NMR602.11: Configuration and Graphics Guideline
NMR602.2:Console Configuration
Test Procedure
TEST Result
No.
Test#
Detail Test Item
OK
NOK
RTST OK
Check the server settings for the items

mentioned below.
1.1
System Configuration DSA settings

Verify Distributed Server configuration as
defined in NMR602.11
1.2
System Users & Security (Server
Configuration)
Verify System Users & security as defined
in NMR602.2 attachment#15 Security and
Access Protection.
1.3
Logical Console (Server Configuration)
Verify all logical consoles have been
configured as defined in PCDD document.
1.4
Console & Flex Station (Server
Configuration)
Verify all Console and Flex Stations have
been configured as defined in PCDD
document
1.5
Server Wide Settings
Verify server Wide setting as per
NMR602.11
1.6
File replication (Redundant servers)
On station go to Configure -> File
Replication
Check LED status for the configured file
replication.
(Expectation : Green LED - for successfully
completion of replication)
1.7
Printers
Verify printer configuration and assignment
for the server as defined in PCDD
document
BY:
DATE:
SIGNATURE:
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13.5 Console & Flex Station Configuration Check
13.5.1 Console / Flex Station NAME

Purpose
NAME
The purpose of this test is to verify the configuration of Console and Flex Station
Pre-requisite
Reference Document
Station must be On
NMR602.2: Console Configuration
Test Procedure
No.
Test#
Detail Test Item
1.1
Go to Station > Connection Properties > Displays

and verify that display search path for system and
custom displays are configured as per section 11.3
of PCDD document
1.2
Verify Experion PKS Station connects to the

correct server - (In Station from the Status Bar
verify the server name) (Expectation: Station is
connected to correct server)
1.3
Note: This test will be verified during server

redundancy check.
Shutdown primary Experion PKS Server and verify
auxiliary setup configuration
(Expectations for Flex Station: after shutdown of
primary server the flex station connects to back-up
server.)
(Expectations for Console Station: after shutdown
of primary server the Console station connects to
local host)
1.4
Note: Applicable only for Console station.

Turn off EPKS servers and verify that Console
Station communicates with C300 (Call up detail
display of C300 controller and observe the status )
Verify asset assignment of the station.

Note: If the station is a part of a console then check
console assignment.
TEST Result
OK
NOK
RTST OK
1.5
BY:
DATE:
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13.6 Printer Configuration Check
13.6.1 Printer - NAME

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify the functioning of Printers.

Station must be On
Test Procedure
No.
Test#
1.1
Detail Test Item
Verify if the network printers are on and

connected to the network.
1.2
Request a display print from station to the
Printer.
Verify the display print-out is produced.
1.3
Repeat above steps for all printer configured.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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13.7 Experion Nodes Check
13.7.1 Server Redundancy Check - NAME

NAME
Purpose
The purpose of this test is to verify that the server redundancy (Server A &
Server B) is working properly.
Pre-requisite
Reference Document
Both servers are powered on and synchronized

Test Procedure
No.
1
Test#
1.1
1.2
1.3
1.4
1.6
1.7
1.8
1.9
Detail Test Item

Call up the Server Redundancy Status display by
selecting View > System Status > Server
Redundancy from the Station menu.
The LEDs in the Link Status group should indicate
the following:
Link 0 (LNK00): - Green & Built
Link 1 (LNK01): - Black & Link Not built
Verify that the LED in the Primary Server group is
green with text Running next to it.
Also verify that the LEDs in the Backup Server group
are green with text Synchronized and Running
next to them.
Shutdown primary (Server B) Experion server.
Secondary server (Server A) will become new
primary server but it will not be synchronized.
Start Server B: Click Start -> Programs ->
Administrator Tools -> Services and verify that all
Experion PKS services with start-up type automatic
are up and running.
Click Start -> Programs -> Honeywell Experion PKS
->Client Software -> Station to verify that station
application works properly.
Select the Synchronize button to synchronize the two
servers. The Experion PKS database on the primary
server will be automatically copied to the backup
server. Within a few minutes the systems should be
synchronized and running in redundant mode. The
synchronization indicator (the first LED for the
Backup Server should change from red to green and
the text change from not synchronized to
synchronized.)
Check the system status during the changeover of
the servers. Observe that the system status shall be
healthy for the other nodes.
Verify auxiliary setup configuration on stations as per
TEST Result
OK
NOK
RTST OK

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NAME
Purpose
The purpose of this test is to verify that the server redundancy (Server A &
Server B) is working properly.
Pre-requisite
Reference Document
Both servers are powered on and synchronized

Test Procedure
No.
Test#
Detail Test Item

section 13.5 Console and Flex Station configuration
check.
1.10
Repeat the above procedure for backup server and
verify.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
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13.7.2 Upgrade of System Software Check - NAME

NAME
Purpose
Pre-requisite
The purpose of this test is to verify the upgrade of firmware in redundant Series
C IOM
The Controller in ON
The redundant IOM to be tested is configured and loaded in the system
The redundant IOM to be tested is in IDLE state
Reference Document
Test Procedure
No.
Test#
1.1
Detail Test Item
Click Start on the task bar and choose Run to open the
Run dialog box
1.2
Click the Browse button to open the Browse dialog box
1.3
Navigate to the directory location -> C:Program
Files\Honeywell\Experion PKS\Engineering
Tools\System\Firmware\CTools
1.4
Launch CTools application by executing CTools.exe file
1.5
Wait for the module listing table to appear in the CTool
window
1.6
Check the module for which firmware to be upgraded
1.7
Select Load FW button to start firmware upgrade
1.8
Monitor progress of the upgrade in the status message
box and the status column.
Upon completion of up gradation, exit from CTool
application.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
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13.8 Network Check
13.8.1 Network Nodes Check

IP Addresses - CCR, PIB11
Purpose
Pre-requisite
Reference Document
No.
Test#
The purpose of this test is to verify IP address, FTE Device Index applicable to
all nodes in the Network.
All nodes are powered on and connected to the network.
Network Design Document
System Architecture Drawing
Test Procedure
TEST Result
Detail Test Item
Verify the IP address of each node as per Network

Design Document as below
1
1.1
For all servers and stations, go to LAN connection
symbol in task bar; double click on the connection
icon and open the network properties for TCP/IP
Internet protocol and verify the IP Address.
1.2
For C300 Controller, Call up the detail display of the
Controller on station and verify the IP address.
1.3
For all Network Switches, call up the detail display
of each switch and verify the IP Address, Subnet
Mask and Default Gateway settings
1.4
Verify FTE Device Index for all FTE nodes using
FTE status display
OK
BY:
DATE:
NOK
RTST OK
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13.8.2 FTE Redundancy Check

FTE Redundancy
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the FTE redundancy is working properly.
Experion Nodes connected on FTE Network
Test Procedure
No.
Test#
1.1
Detail Test Item
Call up the FTE Status Auxiliary Display by click

Start> Programs> Honeywell Experion
PKS>System Management Display>FTE Status
Display.
1.2
Verify status of the FTE connections status OK of
all applicable nodes connected on Ethernet network.
1.3
For any particular node unplug the primary Ethernet
connection, the FTE status display shows that there
is no communication through the primary while the
redundant cable is OK. The status display will give
an OK message once the primary is restored.
1.4
Also, verify the uninterrupted station connection with
server as well as the windows workgroup
connectivity while one of the FTE cable is
unplugged.
1.5
Repeat the same procedure for redundant cable
and verify.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
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13.8.3 FTE Switch Redundancy Check - NAME

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the Network Switch redundancy is working
properly.
All applicable Nodes connected to Network Switch.
Test Procedure
No.
Test#
1.1
Detail Test Item
Call up the FTE Status Auxiliary Display by click Start>

Programs> Honeywell Experion PKS>System
Management Display>FTE Status Display.
1.2
Verify status of the FTE connections status OK of all
applicable nodes connected on Ethernet network.
1.3
For Primary Network Switch unplug the Power Supply
connection.
1.4
The display shows that there is no communication
through the Primary N/w Switch & link status is Silent
whereas the Secondary Network Switch link status is
OK.
The status display will give an OK message once the
Primary Network Switch Connection is restored.
1.5
Also, verify the uninterrupted station connection with
server as well as the windows workgroup connectivity
while Network Switch is powered off.
1.6
Repeat the same procedure for Secondary network
switch and verify.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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13.9 C300 Controller Nodes Check
13.9.1 Controller - NAME

13.9.1.1
Power Check
NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify and document that all the power (AC and DC
voltage) on the IO Panels is present and connected as per System Cabinet
Drawings
Cabinet must be Energized.
System Cabinet Drawings NMR602.6
Test Procedure
No.
Test#
1.1
Detail Test Item
Verify and record all the wiring is as specified in the

System Cabinet Drawing
1.2
With Multi-meter measure the voltage across Line
and neutral. Verify and record the voltage
1.3
With Multi-meter measure the voltage across
Neutral and ground. Verify and record the voltage.
1.4
With the voltmeter measure the voltage across P
(+) and N (-). Verify and Record that the value is
between 24-26 V DC.
1.5
Verify and record the functioning of Fans, Tube
light and Smoke detector.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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C300 Controller Redundancy Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the controller redundancy is working
properly
Controller & Station must be Energized.
Test Procedure
No.
Test#
1.1
Detail Test Item
Call up the C300 Controller detail display from the

Station and ensure that controllers are
synchronized
1.2
In the System cabinet, verify that the status LED
of the primary controller is green and the
secondary controller is Orange.
1.3
Turn off power of the controller 1(Primary) by
removing the fuse.
1.4
Check Status of controller 2 (Secondary )
1.5
Turn on power for the controller 1 by fixing the
fuse.
1.6
Wait until controller boots and they are
synchronized
1.7
Check system status for healthiness of other
nodes and alarm summary for the announcing the
Controller alarms.
1.8
Repeat above steps for controller 2 to switch back
the controllers states as it was before the test
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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C300 IO Link Cable Redundancy Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the IO Link Cable redundancy is working
properly
C300 must be Energized.
Test Procedure
No.
Test#
1.1
Detail Test Item
Monitor the IOLINK to be tested in the Operator

station.
1.2
Disconnect the I/O Link-1A; verify that I/O Link-1A
failure is indicated.
1.3
Reconnect I/O Link-1A cable to C300. Note:
IOLINK Error does not clear.
1.4
Select RESET ERRORS.
1.5
Select ENB PERSWAP
1.6
Wait until errors are cleared.
1.7
Disconnect the I/O Link-1B; verify that I/O Link-1B
failure is indicated.
1.8
Reconnect the I/O Link-1B to C300.
1.9
Select RESET ERRORS.
1.10
Select ENB PERSWAP
1.11
Wait until errors are cleared.
1.12
Repeat above steps for IOLINK-2.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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C300 Power Supply Redundancy Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the Power supply redundancy is working
properly
Test Procedure
No.
Test#
1.1
Detail Test Item
In the System cabinet, verify that the power LED of

C300 Controller is green
1.2
Switch off the Primary Power Supply and verify that
system is healthy and still working
1.3
Note the power supply failure alarm.
1.4
Switch On the Power Supply.
1.5
Repeat above steps for Redundant Power Supply.
1.6
Switch off both the power supplies and mains switch.
Observe that the C300 Controller configuration is
retained by the C300 Memory Backup.
1.7
Manually do warm start of the controller.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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C300 IO Module Redundancy Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the IO Module redundancy is working
properly
C300 & IOMs must be Energized.
Test Procedure
No.
Test#
1.1
Detail Test Item
Call up the detail display of the redundant IOM to

be tested on the operator station and verify that the
status of the both IOMs is OK.
1.2
In the System cabinet, verify that the status LED of
the primary IOM is green and the secondary IOM is
amber.
1.3
Remove the power to the primary IOM by removing
the fuse holder from the IOTA.
1.4
In the system cabinet, the status LED of the
redundant IOM turns to Green indicating that it is
now primary.
1.5
Verify an alarm is triggered indicating a fault
condition of the Primary IOM
1.6
Repeat above steps for the redundant IOM
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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Replacement of Redundant Series C IOM

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify the on line replacement of the redundant
Series C IO Module
Test Procedure
No.
Test#
1.1
Detail Test Item
Call up the detail display of the redundant IOM on an

operator station & verify that the status of the both
IOMs is OK
1.2
Remove the power to the primary IOM by removing
1.3
Loosen the screws at each side of the plastic cover &
remove the IO Module from the IOTA board and
connector
1.4
redundant IOM turns to Green indicating that it is
now primary. Verify that the system is functioning
under normal conditions
1.5
Insert the new IO Module onto IOTA board
1.6
Secure the IO Module to the IOTA board and carrier
by tightening the screws.
1.7
Verify that the new IO Module boots up to the IDLE
state.
1.8
Load the firmware which is the same version as was
running in the old controller.
1.9
In Control Builder, perform a Load with contents.
1.10
Verify the status of the new IOM is OK and it has
become secondary
TEST Result
OK
BY:
DATE:
NOK
RTST OK
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Spare Capacity Check

NAME
Purpose
Pre-requisite
The purpose of this test is to verify the requirement of spare capacity and
expansion is met in C300 controller and IO Modules.
C300 must be energized.
IOMs are energized
Reference Document
Test Procedure
No.
Test#
Detail Test Item
Verify that Controller is not loaded more than 60 % Call up the controller detail display on the station and
1.1
verify the CPU statistics ->check parameter
CPUFREEAVG
Call up the CEE detail display on the station and
1.2
verify the Memory statistics -> check FREEMEMINK
TEST Result
OK
NOK
RTST OK
BY:
DATE:
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13.10 C300 Controller Loop Check
13.10.1
Analog Input
Analog Input Loop Check
Purpose
Pre-requisite
Reference Document
No
Test#
1.1
The purpose of this test is to verify that each Analog input is configured and
working properly.
The Station must be Open. Contractor to provide a gas detector and a four wire
transmitter for loops verification
Spare points will be configured temporarily for this test
IO Assignment, Wiring details, Marshalling Cabinet Drawings
Test Procedure
TEST Result
Detail Test Item
OK
NOK
RTST OK
Open Control module point detail display for desired Analog Input
in the station.
1.2
Connect the signal simulator to the Analog input marshalling
terminals as per the wiring diagrams / details
Note: Spare points will be checked from the RTP location
1.3
Supply a 4mA signal input with the signal simulator 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.
1.4
Repeat above step with 8, 12, 16 and 20mA signals.
1.5
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. This low & high alarm
test can be done for one point and for rest of the points, alarm
limits can be verified by database comparison with the inputs
provided by Contractor.
1.6
Repeat above steps for all Analog Inputs.
BY:
DATE:
SIGNATU
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Analog Output
Analog Output Loop Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that each Analog output is configured and
working properly.
The Station must be Open.
Test Procedure
No.
Test#
Detail Test Item
1
1.1
Set the Loop Calibrator to the current scale.
1.2
Connect the Loop Calibrator to the selected
Analog output point field cable TB terminals in the
marshalling cabinet
Note: Spare points will be checked from the RTP
location.
1.3
Open the Control Module point detail display of
the desired Analog output point.
Force the output signal to a 0% value of the
output range. Verify that the observed value is
equal to the Expected Value at 0%. Record the
value displayed on the digital Multi-meter on the
form.
1.4
Repeat above step for 50% and 100 % values.
1.5
Repeat the above steps for all the Analog outputs
OK
BY:
DATE:
TEST Result
NOK
RTST OK
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Digital Input
Digital Input Loop Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that each Digital input is configured and
working properly.
Test Procedure
No.
Test#
Detail Test Item
1
1.1
Open Control module point detail display for desired
Digital Input in the station
1.2
Connect a jumper across the field cable TB terminals
in the marshalling cabinet for the selected digital
input.
location.
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. This test can be done for one
point and for rest of the points alarm parameters cab
be verified by database comparison with the inputs
provided by Contractor.
1.6
Repeat the above steps for all the Digital inputs
OK
BY:
DATE:
TEST Result
NOK
RTST OK
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Digital Output
Digital Output Loop Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that each Digital output is configured and
working properly.
Test Procedure
No.
Test#
Detail Test Item
1
1.1
Set the digital Multi-meter to the Voltage scale.
1.2
Connect the Multi-meter to the field cable TB
terminals in the marshalling cabinet for the selected
digital Output point.
location.
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
OK
BY:
DATE:
TEST Result
NOK
RTST OK
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13.11 C300 Point Configuration Check

C300 Point Configuration Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the points configured in the system is as
per the database provided by the Contractor and agreed default parameters in
the FDS.
Software database provided by the Contractor
Test Procedure
No.
Test#
Detail Test Item
1
1.1
Exports parameters for Tag name, Description, Eng.
Unit, Asset, Low Range, High Range, Alarm Trip
points, Alarm Priority, State Texts, Control Action,
Input Direction from system in to access database
1.2
Import the Contractor provided database in to the
above access database.
1.3
Compare the two databases and generate report for
the discrepancies if any.
OK
BY:
DATE:
TEST Result
NOK
RTST OK
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13.12 C300 Control Loops Configuration Check

C300 Control Loops Configuration Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that each Control Loop is configured as per
the design inputs provided by contractor and working properly.
The Station must be Open, Server is running with simulation software
Control narratives provided by the Contractor.
Control/Logic diagrams developed and submitted by Honeywell.
Test Procedure
TEST Result
Test#
Detail Test Item
OK
Call up the respective Control Module detail display
Check input, output connections and the point
configuration
1.3
Simulate PV for the input points from the software.
1.4
Observe the calculated value and compare with expected
values as per reference document
1.5
Check alarm as per reference document
1.6
Simulate the PV for the Complex loop from the software
and verify the functionality of the complex loop including
the initialisation.
1.7
Check for BADPV behaviour.
1
No.
1.1
1.2
NOK
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DATE:
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13.13 C300 Logic Configuration Check

C300 Logic Configuration Check
Purpose
The purpose of this test is to verify that each Logic is configured as per the
design inputs provided by Contractor and working properly.
Pre-requisite
The Station must be Open. The Server is running with simulation software
Reference Document
Logic requirements provided by the Contractor.
Test Procedure
TEST Result
No.
Test#
Detail Test
OK
Item
1
1.1
Call up the respective Control Module point detail
display
1.2
Check input, output connections and the point
configuration
1.3
Simulate PV for the input points from the software
1.4
Observe the PV status.
1.5
Observer the output points status as per the
LOGIC requirements
1.6
Simulate the fail condition for the each input and
observe the LOGIC outputs status as envisaged
in the design inputs provided by Contractor
1.7
Check behaviour of the logic for bad input values
NOK
BY:
DATE:
RTST OK
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13.14 C300 Sequence Logic Configuration Check

C300 Sequence Logic Configuration Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that each Sequence Logic is configured as per
the design inputs provided by contractor and working properly.
The Server is running with simulation software
Control narratives provided by the Contractor.
Test Procedure
TEST Result
Test#
Detail Test Item
OK
Call up the respective Sequence Control Module point detail
display
1.2
Simulate PV for the input points from the software
1.3
Observe the output change at respective Control Module
points as per the Sequence Logic
1.4
Check Sequence for Start-up/Hold/Shutdown handlers
conditions
1.5
Check Sequence code if enough documentation/comments is
available (Parameter declaration, usage of variables etc.)
1
No.
1.1
NOK
BY:
DATE:
RTST OK
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13.15 HMI Display Check

HMI Display Check
Purpose
Pre-requisite
Reference Document
No.
The purpose of this test is to verify that each display screen is configured as
specified and working properly.
The Server is running with simulation software.
Display sketches provided by the Contractor
Approved HMI Display Philosophy (PCDD Document)
Contractor comments on the Display prints provided by Honeywell.
Test Procedure
TEST Result
Test#
Detail Test
OK
Item
1
1.1
Call up the Display Schematic on the station screen
1.2
Check the call-up time
1.3
Check for the static layout of the schematic
1.4
Check for the colour code, background colour and
thickness of the various lines as per HMI FDS
1.5
Check displayed data for completeness and
correctness, such as location, accuracy with respect to
the tag names, reading values, target actions, call up of
face plates etc.
1.6
Check appropriate pushbutton / selection / target
functionality
1.7
Check the dynamic behaviour of shapes, data texts, etc.
in the graphic display
1.8
Open the display in the editor mode and verify the
Display performance using Display Performance
Analysis Tool
NOK
BY:
DATE:
RTST OK
SIGNATURE:

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13.16 Safeview Check

Safeview Check
Purpose
Pre-requisite
Reference Document
No.
The purpose of this test is to verify that the safeview works properly
Display Schematics
Approved HMI Display Philosophy (PCDD Document)
Test Procedure
TEST Result
Test#
Detail Test
OK
Item
1
1.1
Verify that the safeview starts up properly
1.2
Verify that the command window is correctly invoked
1.3
Verify that the status bar is invoked correctly
1.4
Verify that different display types allocated to different
windows are invoked correctly
1.5
Verify that the faceplate is invoked correctly
1.6
Verify that minimize and maximize buttons work properly
1.7
Verify that safe view is configured as per PCDD
document
NOK
BY:
DATE:
RTST OK
SIGNATURE:

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13.17 EPKS Security Check

EPKS Security Check
Purpose
The purpose of this test is to verify standard Experion Group Policies, Experion
users accounts and its security access level
The Domain Controller is On.
The Station is open
Pre-requisite
Reference Document
Test Procedure
No.
Detail Test
OK
Item
1
1.1
Log on to Domain Controller using Domain Administrator
account
1.2
Go to Start->All Programs->Admin Tools->Group Policy
Management
1.3
Verify if standard Experion Group Policies are
configured as per expectations
(Expectation: Standard Experion Policies->Honeywell
Product Administrator Role, Honeywell Engineering
Role, Honeywell Operational Role)
1.4
Go to Start->All Programs->Admin Tools->Active
Directory Users and Computers
1.5
Verify if Standards Windows Global groups are
configured
(Expectation: Standard Global Groups->DCS
Administrators, Engineers, Supervisors, Operators, Ack
View Only Users, View Only Users, DCS Domain
Servers)
1.6
On Experion server verify users configuration for
security and control level as per scope of responsibility
TEST Result
Test#
NOK
BY:
DATE:
RTST OK
SIGNATURE:

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13.18 EPKS Diagnostic Check

EPKS Diagnostic Check
Purpose
Pre-requisite
The purpose of this test is to verify Experion system Diagnostic features

The Server is running.
The Station is open
NMR602.11 System Diagnostic Display
Reference Document
Test Procedure
No.
Detail Test
OK
Item
1
1.1
Verify the status of system component, system alarms
on the System status display.
Call up System status display in Station
View > System Status
All alarms indicated on the system status display have
to be verified.
Note: Many alarms will be there during the FAT because
of disconnected field devices or equipment
TEST Result
Test#
NOK
BY:
DATE:
RTST OK
SIGNATURE:

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13.19 FIELD BUS ENGINEERING TESTS
13.19.1
FF Configuration Offline Checks

FF Segment Configuration Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify Off line configuration of FF Segments

Experion server is powered on
Test Procedure
No.
Detail Test
OK
Item
1
1.1
Open FF IO in control builder
1.2
Verify FF Segment Allocation
1.3
Verify FF Device make and Model
1.4
Verify FF Device Addresses
1.5
Check FF device transmitter range, process range,
transmitter unit and process unit
1.6
Check Order in CM configuration
1.7
Check whether correct DD File is being used for
each make of devices.
1.8
Check detail display and faceplate for the tag
1.9
Verify alarm setting if any
1.10
Repeat same procedure for all FF devices
TEST Result
Test#
NOK
BY:
DATE:
RTST OK
SIGNATURE:

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13.20 FF Configuration Online Check

FF Loop Check
The purpose of this test is to verify the online communication for
one from each model device provided by contractor by connecting
to a segment
Experion server is powered on, FIMs are powered on
Purpose
Pre-requisite
Reference Document
Test Procedure
No.
1.1
1.2
1.3
Test#
Detail Test
OK
Item
Note: This test will be done using one sample test device
from each make/model
Assign the sample test devices tags to a test segment in
Control Builder
Wire the devices to test segment physically
Check that the actual device is shown as un-commissioned
under the Monitor tab in Control Builder. (Shown as:

).
Plug & Play: - Verify that FIM assigns address to the device
automatically and device appears on the link as uncommissioned device.
1.5
Device Matching: Match the un-commissioned device in
Monitoring tab to the device in Project tab
1.6
Change the address of the uncommissioned device to match
the address of the project device
1.7
Load the devices to bring device blocks online
1.8
Load the Control Module containing FF Block to ensure the
device is successfully commissioned within the system
1.9
Verify Device operation (e.g. Stroke Valves/MOVs, simulate
process inputs for transmitters)
1.10
Check detail display & shape behaviour
1.11
Check the healthy status of the devices on station
TEST Result
NOK
RTST OK
1.4
BY:
DATE:
SIGNATURE:

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FF Segment Check
FF Segment Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify functionality of FF Segment/FF Link

Experion server is powered on, FIMs are powered on
Test Procedure
No.
TEST Result
Test#
Detail Test
OK
Item
Note: Each segment will be checked with one FF
device connected. The device will NOT be
matched / downloaded; we see that it appears on
the segment as un-commissioned device and thats
all)
Check each segment with one FF device

connected
1.2
Verify FF Segment schedule for all FF Links on all
FIMs.
Purpose: Overall acceptance of FIMs and FF Segments by
Customer
NOK
RTST OK
1.1
BY:
DATE:
SIGNATURE:

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FIM Redundancy Test - NAME

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the FIM redundancy is working properly.
FIMs must be synchronized
Test Procedure
No.
Test#
1.1
Detail Test Item
TEST Result
OK
Call up the detail display of the redundant FIM to

be tested on the operator station and verify that the
status of the both FIMs is OK.
1.2
Ensure primary and secondary FIMs are
synchronised
1.3
In the System cabinet, verify that the status LED of
the primary FIM is green and the secondary FIM is
amber.
1.4
Remove the power to the primary FIM by removing
1.5
redundant FIM turns to Green indicating that it is
now primary. Verify detail display also.
1.6
Verify an alarm is triggered indicating a fault
condition of the Primary FIM
1.7
Repeat above steps for redundant FIM
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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FF Bulk Power Supply Redundancy Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the Bulk Power supply redundancy is
working properly
FIMs must be Energized.
Test Procedure
No.
Test#
1.1
Detail Test Item
In the FFPS cabinet, verify that the power LED of

the FIM is green
1.2
Switch off the Primary Power Supply and verify
that system is healthy and still working
1.3
1.4
Switch On the Power Supply.
1.5
Repeat above steps for Redundant Power Supply.
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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FF Power Conditioner Module Redundancy Check

NAME
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the FF Power Conditioner Module
redundancy is working properly
FIMs must be Energized
Test Procedure
No.
Test#
1.1
1.2
Detail Test Item
Call up FF IO point detail on station

Unplug FF power conditioner module of the
corresponding segment
1.3
Verify that the segment is still communicating
(check the device status) and there is no effect on
the point detail Display
1.4
1.5
Plug the FF power conditioner module again
1.6
Repeat above steps for redundant power
conditioner module of the segment
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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13.21 ESD(SM) Communication Check
13.21.1
SM SM NAME
Purpose
Pre-requisite
Reference Document
No.
1
Test#
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
To verify that the communication between ESD systems and DCS systems is
configured and working properly.
Experion Servers and stations must be powered on.
C300 Controllers must be powered on.
SM Controllers must be powered on and connected to Experion network via
Control Firewall.
Network must be powered on.
NMR602.3
Test Procedure
TEST Result
Detail Test Item

Verify that the Safety Manager is powered on
Verify that the communication link from Experion server
to Safety Manager (ESD) system is active and working
from the station view
Verify the channel / controller configuration for ESD
system in Experion Server as per Third party system
interface details
Verify that the communication between C300 and Safety
Manager (ESD) system using PCDI is active and working
from the control builder
Call up an analog/digital SCADA points on the station
view of an operator station
Force a value from the ESD (SM) system point and
check the value change on the station view of an
operator station
Force a PCDI value from the Safety Manager (ESD)
system and check the value change in the Control
Builder of Experion System
Remove primary communication cable from the Control
Firewall and verify that the ESD channel reports a failure
in communication for the primary connection
Verify that removing the Primary communication cable,
does not cause loss of view for the ESD values in the
Experion Station view
Verify that an alarm is generated for the failure of the
primary communication
Restore the primary communication channel to normal
condition
Repeat above steps for the secondary communication
cable
OK
NOK
RTST OK

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SM NAME
Purpose
Pre-requisite
Reference Document
To verify that the communication between ESD systems and DCS systems is
configured and working properly.
Experion Servers and stations must be powered on.
C300 Controllers must be powered on.
SM Controllers must be powered on and connected to Experion network via
Control Firewall.
Network must be powered on.
NMR602.3
Test Procedure
TEST Result
No.
Test#
Detail Test Item
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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Quick Builder Database Check

Quick Builder Database Check
Purpose
Pre-requisite
Reference Document
The purpose of this test is to verify that the points configured in the system is as
per the database provided by the Contractor and agreed default parameters in
the FDS.
Software database provided by the Contractor, FDS
Test Procedure
No.
Test#
Detail Test Item
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Analog Input Check

Description
Ranges
Alarm Settings
PV address
OP address (source & Destination)
SP address (source & Destination)
Mode address (source & Destination)
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Digital Input Check

Description
State Descriptions
Width of PV parameter
Width of OP parameter
PV address
OP address (source & Destination)
Mode address (source & Destination)
3
Verify Supporting Logics according to PCN
TEST Result
OK
BY:
DATE:
NOK
RTST OK
SIGNATURE:

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14 APPENDIX 04 C300 LOOP CHECK record

C300
Controller
Point
Type
IOM
Channel
CM Name
The detail list will be provided during FAT.
Marshalling
Cabinet
Marshalling
TB No
TM1 TM2 TM3
Result

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C300 Controller
CM Name
Result
96

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16 APPENDIX 06 C300 LOGIC CONFIGURATION check record

C300 Controller
CM / Logic Name
Result
96

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17 APPENDIX 07 C300 SCM CONFIGURATION check record

C300 Controller
The detail list will be provided during FAT
SCM Name
Result
96

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18 APPENDIX 08 hmi DISPLAY CHECK record

Sr. No.
Graphic Name
Graphic Title
Result

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19 APPENDIX 09 FF CONFIGURATION CHECK record

FIM
FF Segment
CM Name
Device
Result

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FIM
FF Segment
Result
96

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21 APPENDIX 11 Quick builder DATABASE CHECK record

CHANNEL
CONTROLLER
TAGNAME
Result

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22 APPENDIX 12 deficiency log

Project
Item No
Project No
JAZAN
Raised By
Date
Summary:
Description:
Category : Change
Change Authorized By :
Fault
Clarification
Work to Complete
Date
Proposed Remedial Action/Response:
Action By: Honeywell

Contractor
Summary of Corrective Action:
Honeywell Signature
SA
Date
Others
Contractor/Aramco Signature
Date

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23 APPENDIX 12 System log
Sl
No
Date
Project
Stage
Problem
report No
Description of
problem
Resolution
Corrective
action taken
Completion
date
Re
mark

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Project
Project No
JAZAN Project
Item No
Raised By
Date
Summary:
Description:
Category : Change
Change Authorized By :
Fault
Clarification
Work to Complete
Date
Proposed Remedial Action/Response:
Action By: Honeywell

Contractor
Summary of Corrective Action:
Honeywell Signature
Date
SA
Others
Contractor/Aramco Signature
Date
96

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25 APPENDIX 05 - Applicable System Standards

Saudi Aramco Materials System Specifications
23-SAMSS-010
Distributed Control System (DCS)
23-SAMSS-060
Applications Integration Middleware
23-SAMSS-070
Laboratory Information Management System (LIMS)
23-SAMSS-071
Data Validation and reconciliation Software
23-SAMSS-072
Data Acquisition and Historization System (DAHS)
34-SAMSS-619
Burner Management Systems for Water tube Boilers
34-SAMSS-623
Programmable Controller Based ESD Systems
34-SAMSS-625
Machinery Protection System
34-SAMSS-820
Instrument Control Panel Indoors
34-SAMSS-821
Instrument Control Panel Outdoors
34-SAMSS-830
Programmable Logic Controllers
34-SAMSS-913
Instrumentation and Thermocouple Cable
Saudi Aramco Engineering Standards
SAES-B-014
Safety Requirements for Plant and Operations Support Buildings
SAES-J-002
Technically Acceptable Instruments
SAES-J-003
Basic Design Criteria
SAES-J-004
Instrumentation Symbols and Identification
SAES-J-005
Instrumentation Drawings and Forms
SAES-J-505
Combustible Gas and Hydrogen Sulfide in Air Systems
SAES-J-601
Emergency Shutdown and Isolation Systems
SAES-J-602
Burner Management, Combustion and Waterside Control Systems for Water
tube Boilers
SAES-J-603
Process Heaters safety System
SAES-J-604
Protective and condition Monitoring Equipment for Rotating Machinery
SAES-J-607
Burner Management Systems for SRU Trains
SAES-J-801
Control Buildings
SAES-J-902
Electrical Systems for Instruments
SAES-J-904
FOUNDATION Fieldbus (FF) Systems
SAES-Z-001
Process Control Systems
SAES-Z-002
Technically Acceptable Process Control Systems
SAES-Z-010
Process Automation Networks Connectivity
SAES-Z-020
Design and Installation of Fiber optic Systems for Process Control Systems
Saudi Aramco Engineering Procedure

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SAEP-1624
SAEP-1626
SAEP-1628
SAEP-1630
SAEP-1634
SAEP-1636
SAEP-1638
SAEP-3101
SAEP-16
SAEP-302
SAEP-349
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Preparation of System Design Document

Configuration and Graphic Guidelines
Preparation of Integration Specifications Document
Preparation of Integration Test Procedure
Installation and Checkout Plan
Site Acceptance Test
Equipment & Spare Parts Data Requirement for Contractor Produced
Equipment
Project Execution Guide for Process Automation Systems
Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Eng.
Requirement
Advanced Process Control (APC) Systems
American National Standards Institute (ANSI) / National Electrical Manufacturers Association

(NEMA)
ANSI / NEMA ICS 2
Industrial Control Devices
ANSI / NEMA ICS 6
Enclosures or Industrials Controls and Systems
American National Standards Institute (ANSI) / National Fire Protection Association (NFPA)
ANSI / NFPA 70
National Electric Codes
Instrument, Systems and Automation Society (ISA)
ISA S5.1
Instrumentation Symbols and Identification
International Organization for Standardization
ISO 9000
Quality Systems Model for quality assurance in design/development,
production, installation and servicing.
International Electro-technical Commissions (IEC)
IEC 61000-6-2
Generic standards Immunity for Industrial Environments

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26 APPENDIX 06 Project Specification

The design of system is based on bellow project specifications.
Sr. No
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
27
28
29
30
31
32
33
34
35
36
37
Description
Automation Design Criteria
Emergency Shutdown System
Process Control System Overview
Process Control System Integration
PCS Configuration Guidelines
Control and Marshalling Cabinets Specification in
Fieldbus Foundation Specification
Hart Specification
Smart Valve Monitoring System SVMS
Smart Shutdown Valve Monitoring System SZVMS
Alarm Management System
Data Acquisition & Historization System
Instrument Asset Management
Fire Detection System
Gas Detection System
PCS System Design Document
Emergency Notification Alarm System
Instrument Block Diagram Emergency Notification Alarm
CCR ENG/MAN Console
Typical PIB Maintenance Console
DCC Console
Emergency Communication Console CCR
Maintenance Training Console
Control and Instrumentation Philosophy
Automation Scope Of Supply SRU, Utilities and offsite
Document No
PP-118009
PP-118158
PP-118159
PP-118160
PP-118161
PP-118163
PP-118164
PP-118167
PP-118168
PP-118169
PP-118170
PP-118171
PP-118172
PP-118173
PP-118174
PP-118175
PP-118180
PP-118181
PP-118228
PP-118231
PP-118281
PP-118282
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118393
PP-118394
PP-418002
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FAT
Sr. No
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Description
PCS I/O Summary WUC Scope
Process Control System Vendor Services
Operator Training Simulator
Condition and Vibration Monitoring System (CMS/VMS/FFVMS)
Inspection and Testing of Electronics Systems
Compressor Control System (CCS)
CCR Layout
Control Room Layout
96
Document No
PP-118390
PP-118162
PP-118166
PP-118176
PP-118151
PP-118178
PP-111011
PP-118900
OF
96

Reference Doc 01055 XX DCS FAT Rev00A

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Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

: Honeywell Turki Arabia Ltd.

: Aramco Overseas Company

: Jazan, Saudi Arabia

:Jazan Refinery and Marine Terminal Project

Purchase Order No.

Equipment/Material Name and Item and or Tag Number :

: Power Requirements - MPS

Vendor's Document No. : 0105513DCSFAT

JAZAN REFINERY AND MARINE TERMINAL PROJECT

: FR, FA, FC, FN, AB

A:Approved without Comment; B: Approved with Minor Comment

HTC DOC. NO.

HTC Doc. No.

DCS Factory Acceptance Test Plan Rev00 A

Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

Internal Revision History

Issue Revision History

DCS Factory Acceptance Test Plan Rev00 A

Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

DCS Factory Acceptance Test Plan Rev00 A

Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

DCS Factory Acceptance Test Plan Rev00 A

Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

DCS Factory Acceptance Test Plan Rev00 A

Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

19 APPENDIX 09 FF CONFIGURATION CHECK record.......................86

DCS Factory Acceptance Test Plan Rev00 A

Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

DCS Factory Acceptance Test Plan Rev00 A

Jazan Refinery and Marine Terminal

HTAL Project: 182526

CUSTOMER DOC NO.

HWL DOC. NO.: 0105513DCS

DCS FACTORY ACCEPTANCE TEST PLAN

Saudi Aramco Standards