You are on page 1of 21

FACTORY ACCEPTANCE

TEST REPORT

Client : PETRONAS GAS BHD

Supplier : SEDIA TEGUH SDN BHD

Contract No. : SMSO/PGB-POD/2013/079

Project Title : GPP PLC UPGRADE

System Name : K5/6-1301C

Building Name : B56-2305

Project No. : STP052

Document No. : STP052-13-G01-008

CLIENT APPROVAL

R : Revise and resubmit, work may proceed


Name: __________________________ Date:______________

N : Revise and resubmit, work may not proceed


Signature: ___________________________________________

I : Retained for information only, no further issue

A : Review and accepted, work may proceed Company Chop:______________________________________

REVISION RECORD
ISSUE ORIGINATED CHECKED APPROVED
REV DESRIPTION
DATE BY BY BY

A ISSUE FOR APPROVAL 13/08/2013 LEO KL GOH SK TAI


B APPROVAL FOR CONSTRUCTION 13/08/2013 LEO KL GOH SK TAI
0 AS BUILT 22/10/2013 LEO KL GOH SK TAI
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

EQUIPMENT DESCRIPTION JOB NO:


STP052
ControlLogix PLC for K5/6-1301C
CUSTOMER ORDER NO: DATE:

SMSO/PGB-POD/2013/0079

ITEM REMARKS
1. VISUAL CHECK
SURFACE
FINISHING
PAINTING
WELDING
DIMENSION
STRUCTURAL
2. GENERAL LAYOUT
EQUIPMENT
WIRING
INSTRUMENT

3. CABLING ROUTING/ARRANGEMENT

4. ELECTRICAL TERMINATION CHECK

5. OPERATIONAL CHECK

6. FUNCTIONAL CHECK

THE INSPECTION WAS CONDUCTED ON2013, AND

COMPLETED INCOMPLETED

MATERIAL SHOWN ACCEPTED IS RELEASED TO BE SHIPPED AS INSTRUCTED.

INSPECTOR: VENDOR:

(Client) Sedia Teguh Sdn Bhd.

SIGNATURE: SIGNATURE:

DATE: DATE:

1 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

Content

1.0 INTRODUCTION 2

1.1 SCOPE 2

1.2 TEST EQUIPMENTS 3

2.0 DOCUMENTATION LIST 4

3.0 PHASE 1 - VISUAL INSPECTION 5

3.1 MECHANICAL CONSTRUCTIONS CHECK 5

4.0 PHASE 2 - STANDARD HARDWARE & SOFTWARE FUNCTIONAL TEST 6

4.1 MODULE INSTALLATION 6

4.2 POWER UP SYSTEMS 6

4.3 LOADING UP APPLICATION PROGRAM 6

5.0 PHASE 3 PROGRAMMING LOGIC TEST 7

6.0 PHASE 4 THIRD PARTY INTERFACING TEST 8

6.1 BENTLY NEVADA COMMUNICATION TEST 8

6.2 DCS COMMUNICATION TEST 9

7.0 PHASE 5 SYSTEM REDUNDANCY TEST 11

7.1 HOT REDUNDANCY 11

8.0 PHASE 6 - POWER FAILURE TEST 12

9.0 PHASE 7 - FINAL INSPECTION 13

9.1 TEST METHOD 13

9.2 FINAL CHECK 13

10.0 SHIPMENT RELEASE 14

APPENDIX A - PUNCH LIST 15

APPENDIX B - EQUIPMENT FUNCTIONAL CHECKLIST 175

APPENDIX C - PRINTED EXISTING PLC5 PROGRAM AND NEW 16

2 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

1.0 Introduction

1.1 Scope

The purpose of this document is to describe the extent of the testing to be carried out on the
system and provide a record of the Factory Acceptance Test. The Sedia Teguh Sdn Bhd
signature would be signed by Sedia Teguhs engineer when a test has been carried out. The
Client would then sign to denote that the test conducted by Sedia Teguhs engineer has been
witnessed and accepted.

This document covers the testing of all inputs and outputs of the hardware and software. The
tests shall be divided in 6 phases. In-house internal test report shall be submitted for review prior
to the FAT witnessed by Client.

Phase 1 (Visual Inspection)


In this phase, visual inspection will be done on general system integration and comment
accordingly.

Phase 2 (Standard Hardware & Software Functional Test)


This phase is to test all hardware to ensure that all of it is working properly. This is accomplished
by checking the status of the healthy indication.

Phase 3 (Programming Logic Test)


This phase is to test the programming logics.

Phase 4 (Third Party Interfacing Test)


This phase is to test third party interfacing test.

Phase 5 (System Redundancy Test)


This test is to verify the system redundancy is function correctly.

Phase 6 (Power Failure Test)


This phase is to verify the response of ControlLogix Controller when power failure happens.

Phase 7 (Final Inspection)


To perform the final inspection before packing and delivery

3 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

1.2 Test Equipments

An Engineering Workstation (EWS) running the RSLogix 5000 programming software shall be
used for communicating with the system, downloading program and monitoring system variables
and application logic.

All test equipment to be used for the testing shall be listed below. All test equipment shall be
properly calibrated and tested with valid calibration certificates if appropriate. Under no
circumstances shall non-calibrated test instruments be used.

Device Serial Numbers Calibration Expire Date


Multimeter 14280027 05/04/2013
Engineering Workstation N/A N/A

4 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

2.0 Documentation List

The following are a list of documents which will be used as a reference during the tests.

S/No. Description Doc. No. Rev. No


1. System Architecture STP052-13-B01-008 A
2. General Arrangement Drawings STP052-13-B02-008 A
3. Power Distribution Drawings STP052-13-B03-008 A
4. Functional Design Specification STP052-13-C04-008 A
5. Hardware I/O Assignment List STP052-13-C05-008 A

A complete set of system drawings stamped "Test Copy" shall be issued by the Engineering
Department. They shall be referred to as the "Test Copy Drawings" (TCD).

Any non-conformance found in the systems shall be identified on the TCD and corrected with red
or blue ink (red-additions and blue-deletions).

5 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

3.0 Phase 1 - Visual Inspection

Visually inspect the mounting plate and assembly items to ensure the layout is similar to the
approved drawings (TCD). For hardware, check the power distribution and earthing. Any
discrepancies shall be markup in the TCD and listed in the punch list for corrective action.

3.1 Mechanical Constructions Check

In this phase all layout drawings shall be checked against actual layout. The checks verify all
physical layouts of modules, and I/O cards in the panel.

S/N DESCRIPTION OF TEST Accept Reject Remark


01 Arrangement of internal modules
02 Quantity check
03
04
05
06
07
08

TEST RESULT: Accept / Reject


REFERENCE: STP052-13-B02-008 General Arrangement Drawings

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

6 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

4.0 Phase 2 - Standard Hardware & Software Functional Test

This phase of the test comprises of the following:

4.1 Module Installation


Module and chassis serial numbers shall be documented on allocation sheets, signed, dated and
retained along with this procedure for future reference. Form to be used for record, STP045-12-
EFC-002 Equipment Functional Checklist. Install all electronic modules and ensure they are
properly clamped and seated.

TEST RESULT: Accept / Reject


CHECK SHEET: STP052-13-EFC-008 Equipment Functional Checklist

4.2 Power Up Systems


Ensure that the incoming power supply is regulated 24VDC before it is switched on. Check and
confirm that 24VDC power supply is supplied to each instrument using the multi-meter.

Upon successful power up of the Processor, check the module status LEDs. The OK LEDs in
yellow indicates a healthy condition and solid green, flashing red or solid red flashing indicates a
faulty condition.

TEST RESULT: Accept / Reject


CHECK SHEET: STP052-13-EFC-008 Equipment Functional Checklist

4.3 Loading Up Application Program


Before loading the program to controller, connect a Ethernet cable to the RJ45 port on
Ethernet/IP module and to a EWS running RSLogix5000 software. Using the EWS, open the
RSLogix5000 program and load the Projects. With the Controller module key switch in the
Remote position, initiate download of the application logic into the Controller. Upon a successful
download, check the module status LED's and make sure the no faults and I/O error.

For HMI unit, before loading the program to controller, connect an Ethernet cable to the RJ45 port
on HMI unit and to a EWS running Factory Talk View Site Edition Operator Interface Engineering
Software. Using the EWS, open the Factory Talk View Site Edition Operator Interface
Engineering Software and open the Applications. Initiate download of the application developed
into the HMI. Upon a successful download, check the error logged and make sure no faults and
error

INTERNAL TEST RESULT: Accept / Reject


CHECK SHEET: STP052-13-EFC-008 Equipment Functional Checklist

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

7 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

5.0 Phase 3 Programming Logic Test

This test is to verify the RSLogix 5000 programs and the functionality of the logic and controls.

5.1 Test Method

The Logic Tests shall be conducted and verified together with existing PLC5 program and new
ControlLogix program.

Compare both existing PLC5 program and new ControlLogix program rung by rung. Verify that all
ladder diagram is similar for existing and new program; with new tag assigned for ControlLogix
program.

TEST RESULT: Accept / Reject


Reference: Existing PLC5 Program and New ControlLogix Program

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

8 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

6.0 Phase 4 Third Party Interfacing Test

6.1 Bently Nevada (BN) Communication Test

This test is to verify the communication between the PLC and Bently Nevada.

The Communication Tests shall be conducted and verified together with the Software I/O
Schedule.

Communication test shall be performed by first make sure the hardware status is healthy and the
communication settings are correct.

For BN communication test, based on the Modbus I/O list, for feedback signal, simulate the value
by forcing the signal from BN. Verify that value change for the particular point by monitoring the
system variables on the EWS.

TEST RESULT: Accept / Reject


Check Sheets: Software I/O Assignment List

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

9 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

6.2 DCS Communication Test

The Communication Tests shall be conducted and verified together with the Modbus I/O
Schedule. Modbus Simulator software will be used for the testing to works as third party DCS
software.

For DCS communication test, based on the Modbus I/O list, for commands signal, simulate the
value by forcing the signal from Modbus Simulator software or DCS (if available). Verify that value
change for the particular point by monitoring the system variables on the EWS. For feedback
signal, simulate the value by forcing the value in EWS. Verify that value change for the particular
point by monitoring the system variables on the Modbus Simulator software or DCS (if available).

Control Narrative between DCS and SCADA shall be tested according to the narrative agreed.

TEST RESULT: Accept / Reject


Check Sheets: Software I/O Assignment List

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

10 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

7.0 Phase 5 System Redundancy Test

This test is to verify the system redundancy is function correctly.

7.1 Hot Redundancy

Verify the hardware is installed according to the TCD. Whenever the power applied, the primary
chassis should switch the power on first followed by the secondary chassis (whichever chassis is
switched on first will become the primary one).

When the system is completely powered up and booted, the Primary RM will display a message
of PRIM, and the CNB will display PwQS or Primary with Qualified Secondary. The
Secondary RM will display a message of SYNC, meaning it has synchronized with the primary
system, and secondary CNB will display a message of QS, or Qualified Secondary

To simulate the actual problem which will cause the switchover occur, remove the ControlNet tap
from CN2R, observe the primary and secondary chassis. The SRM that was primary now say
disqualified. The secondary chassis RM should now say PRIM. This is because the secondary
chassis has taken over primary control of the system. The front of the CN2R should state PwDS
which means Primary with Disqualified Secondary

Replace the ControlNet tap on the CN2R. The original CN2R will display a qfng message stating
that it is trying to qualify and then a QS which means Qualified Secondary. The RM will say
SYNC, which means it is synchronized and ready to switchover.

The original Secondary chassis is the current Primary chassis, and the original Primary chassis is
now the Secondary chassis.

Repeat the redundancy test above by pulling the primary processor to simulate the failed
processor and monitor the status of the module indication and also the output status.

TEST RESULT: Accept / Reject

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

11 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

11.0 Phase 8 - Power Failure Test

This test is to verify the response of PLC & HMI when power failure happens and restore back.
Verification will include communication and all the I/O.

11.1 Test Method

Simulate a power failure by switching off the supply power. Wait for about 5 ~ 10 minutes. Switch
on the power again. Check on the communication link and all the I/O signals. All the
communication link and I/O signal should be automatically restore once the power is switched on.

TEST RESULT: Accept / Reject

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

12 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

12.0 Phase 10 - Final Inspection

This inspection will take place at the end of the test period and will finalize the release of the
product to the customer. The inspection will also ensure that the total quantity of item is correct
against the Bill of Material.

12.1 Test Method


Disconnect all test panel and test connection. Tidy up the panel wiring and dress for final
Inspection.

Perform the final inspection and ensure the quantity of items is correct and that the system is
ready for packing.

Rectify any punch list where practical.

For those items that are deemed not practical at this stage, agreement will be reached with
customer for rectification at site.

TEST RESULT: Accept / Reject

12.2 Final Check


All equipments to be powered off.
All test leads and equipment to be removed.
All covers, screws etc removed during testing to be correctly reinstalled.
All locking bars etc to be in place for shipment.

TEST RESULT: Accept / Reject

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

13 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

13.0 Shipment Release

This is to certify that the system has been tested according to the Factory Test procedures. The
System is now released for shipment subjected to the following conditions:-

TEST RESULT: Accept / Reject

REPRESENTATIVES NAME SIGNATURE DATE

SEDIA TEGUH SDN BHD

ACCCEPTANCE BY CLIENT

WITNESS BY

14 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

Appendix A - Punch List

15 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

Appendix B - Installation Hook-up Inspection Form

16 of 17
Project: GPP AB PLC5 SYSTEM UPGRADE Doc.No.: STP052-13-G01-008
Item: ControlLogix PLC for K5/6-1301C Rev.No.: 0
Client P/O No.: SMSO/PGB-POD/2013/0079

FACTORY ACCEPTANCE TEST (FAT) REPORT

Appendix C- Equipment Functional Checklist

17 of 17
SEDIA TEGUH SDN BHD Company No. 195647H Document No.
: STP052-13-
G01-008
No. 6 & 6-1, Jalan Wangsa Delima 2A, Rev. No. :0
KLSC III, Section 5,Wangsa Maju,
Page No. : 1 of 1
53300 Kuala Lumpur.
Tel : 603-4143 6896/ 6897
Fax : 603-4143 6898
E-mail : sales@sediateguh.com.my

PUNCH-LIST

Project Name GPP AB PLC5 System Upgrade Customer Name Petronas Gas Berhad

Project No. STP052 Customer PO No. SMSO/PGB-POD/2013/0079

Items ControlLogix PLC for K5/6-1301C

S/No Description Status Sign


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Client Representatives Name: Engineer-in-charges Name:

Signature: Signature:

Date: Date:
Document No. :
STP052-13-G01-008
EQUIPMENT FUNCTIONAL CHECKLIST Rev. No. : A
Page No. : 1 of 1

Project Name GPP AB PLC5 System Upgrade Customer Name Petronas Gas Berhad
Project No. STP052 Customer PO No. SMSO/PGB-POD/2013/0079
Item ControlLogix PLC for K5-6-1301C

Harware Test
Remarks
No. Tag Name Description Brand Model Serial Number Position Power Normal Faulty Last Checked
1 Chassis 1756 4 slots Allen Bradley 1756-A4 26327984 PC1
2 VAC Power Supply 85-265 (5V @ 10 Amp) Allen Bradley 1756-PA72 26391812 PC1
3 Chassis 1756 4 slots Allen Bradley 1756-A4 26755807 PC2
4 VAC Power Supply 85-265 (5V @ 10 Amp) Allen Bradley 1756-PA72 26653743 PC2
5 ControlNet Interface Module Allen Bradley 1756-CN2R 26741316 PC1S0
6 ControlNet Interface Module Allen Bradley 1756-CN2R 26741305 PC2S0
7 Processor Logix5571 With 2 Mbytes Memory Allen Bradley 1756-L71 26742691 PC1S1
8 Processor Logix5571 With 2 Mbytes Memory Allen Bradley 1756-L71 26922622 PC2S1
9 EtherNet 10-100M Bridege Module Allen Bradley 1756-EN2T 26921342 PC1S2
10 EtherNet 10-100M Bridege Module Allen Bradley 1756-EN2T 27057240 PC2S2
11 Redundancy Module Allen Bradley 1756-RM2 26966758 PC1S3
12 Redundancy Module Allen Bradley 1756-RM2 26966857 PC2S3
13 Redundancy Module Cable, 1M Allen Bradley 1756-RMC1 2 UNIT
14 Mounting Assembly for 1771 to 1756 I/O Field Wiring ConvAllen Bradley 1492-MUA1B-A4-A7 -
15 Chassis 1756 7 slots Allen Bradley 1756-A7 26653816 C1
16 VAC Power Supply 85-265 (5V @ 10 Amp) Allen Bradley 1756-PA72 26317554 C1
17 ControlNet Redundant Interface Module Allen Bradley 1756-CN2R 26317554 C1S0
18 VDC Input 10-31 16 Pts (20Pin) Allen Bradley 1756-IB16 27590310 C1S1
19 Elec Fused Output 10-31 VDC 16 Pts (20 Pin) Allen Bradley 1756-OB16E 28419667 C1S2
20 Analog Input - Current/ Voltage 16 Pts (36 Pin) Allen Bradley 1756-IF16 26272055 C1S3
21 Empty Slot Filler For 1756 Chassis Allen Bradley 1756-N2 - C1S4
22 Empty Slot Filler For 1756 Chassis Allen Bradley 1756-N2 - C1S5
23 Communication Module DH+ and RIO Allen Bradley 1756-DHRIO 27278317 C1S6
24 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CM1771-LA001 -
25 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CONACAB005B -
26 ControlNet T-Tap/Straight Allen Bradley 1786-TPS 6 UNIT
27 ControlNet 75 OHM Terminator Plug Allen Bradley 1786-XT 4 UNIT
28 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CM1771-LD001 1 UNIT
29 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CONACAB005X 2 UNIT
30 Conversion Module for 1771 to 1756 I/O Field Wiring Conv Allen Bradley 1492-CM1771-LD006 1 UNIT
Tested By: Witnessed By: Approved By:

Name Name Name

Designation Designation Designation


Date Date Date