Site Acceptance Test (SAT)

SITE ACCEPTANCE TEST
Client Name Bayer
Vendor’s Name Exergy LLC / Hydropure Systems
Project Name Bayer Shawnee R&D
PO No 140524-P-100
Document
Site Acceptance Test
Name
Document No HPS-PR 247-SAT Rev 0
Reference 02922 Rev B
Drawing No 02923 Rev B
Issue Date October 31, 2014
R-0 For approval

Rev No. Issue Date Description Remarks
Client Name Bayer
Project POINT OF USE COOLER
Document Name Site Acceptance Test ( SAT )
Document No. HPS-PR 247-SAT Rev No - 0
Issue Date October 31, 2014 Page 2 of 23
TABLE OF CONTENT
1.0 APPROVAL .......................................................................................................... 4

2.0 SAT PLAN............................................................................................................ 5
2.1 INTRODUCTION.................................................................................................. 5
2.2 ABBREVIATIONS ................................................................................................. 5
2.3 REFERENCE DOCUMENTS .................................................................................. 5
2.4 PURPOSE OF THE TESTS ..................................................................................... 5
2.5 OBJECT DESCRIPTION ........................................................................................ 6
2.6 SAT PERFORMANCE ........................................................................................... 6
2.6.1 RESPONSIBILITIES............................................................................................... 6
2.6.2 GOOD TESTING PRACTICE .................................................................................. 6
2.6.3 HOW TO FILL IN THE TESTS / INSPECTIONS ....................................................... 7
2.6.4 DEVIATION HANDLING....................................................................................... 8
2.7 ACCEPTANCE CRITERIA ...................................................................................... 8
2.8 SAT RESULT ........................................................................................................ 8
3.0 TESTS .................................................................................................................. 9
3.1 MECHANICAL & DOCUMENTATION INSPECTIONS .......................................... 10
3.1.1 FAT CLOSURE .................................................................................................. 10
3.1.2 VERIFICATION OF COMPONENTS AS PER P & ID ............................................. 11
3.1.3 VERIFICATION OF ELECTRICALS ....................................................................... 12
3.1.4 VERIFICATION OF COMPONENT SPECIFICATIONS ........................................... 13
3.1.5 REVIEW OF TEST CERTIFICATES & TEST REPORTS ........................................... 14
3.1.6 CHECK FOR AVAILABILITY OF MANUAL & DATA.............................................. 15
3.2 SYSTEM ACCEPTANCE TEST ............................................................................. 16
3.2.1 TO CHECK FUNCTIONAL LOGIC & ALARM ....................................................... 16
3.2.2 TO CHECK THE I/O ........................................................................................... 17
3.3 OPERATION TEST ............................................................................................. 18
3.3.1 LEAK TEST......................................................................................................... 18
3.3.2 CHECK FOR SYSTEM OPERATING PARAMETERS………………………………….……….19
4.0 SAT REPORT ..................................................................................................... 20
4.1 PURPOSE OF THE REPORT ............................................................................... 20
4.2 DEVIATIONS ..................................................................................................... 20
Client Name Bayer
4.3 RETESTS............................................................................................................ 22
4.4 FINAL APPROVAL ............................................................................................. 23
Client Name Bayer
1.0 APPROVAL
Signatures on this page indicate that this document has been reviewed, checked and
approved by the concerned persons. It shall be signed and dated as shown below.
Department Name Designation Signature Date
Exergy, LLC
Project Engineer
Project Manager
Bayer
Engineering
Validation
QA
Client Name Bayer
2.0 SAT Plan
2.1 Introduction
Point of Use cooler is specially designed for cooling of PW/WFI water in loop at
required temperature. It contains Sanitary Type Double Tube Sheet Heat Exchangers,
which reduces PW Water temperature from 65 Deg. C to 30 Deg. C at maximum flow
rate of 5 GPM. Chilled Water at the inlet of Heat Exchanger is required at
Temperature of 5.5 Deg. C at a flow rate of 8.6 GPM.
The SAT shall show that the Point of Use Cooler is manufactured and operates in
accordance with the design specifications, functional logics and operating
Instructions.
The SAT is divided into three test sections:
 Mechanical & Documentation Inspections

 Hardware Acceptance Test
 Operation Test
2.2 Abbreviations
SAT Site Acceptance Test
MOC Material of Construction
TC Tri Clover
Ra Average Roughness
NLT Not Less Than
2.3 Reference Documents

1. P & ID
2. Design Qualification
3. Test Certificates
4. Manuals & data sheet check
5. GA Drawings
6. Control Wiring Diagram
7. FAT Report
2.4 Purpose of the Tests
The purpose of the SAT is to test, inspect and show that the Point of Use Cooler is
installed correctly according to mechanical and electrical specifications, that
components are marked and located according to the valid P & ID and that the
system works according to the Functional Logics.
Client Name Bayer
2.5 Object description
Product : Point of Use Cooler

Function : for cooling product water in loop
Manufacturer : Exergy LLC / Hydropure Systems
Project number :
Year of manufacture :
2.6 SAT Performance
The tester shall first read this SAT Plan section, then perform the tests and finally fill in
the Report in the end of this document. The performance of the specific Factory
Acceptance Tests is described for each test in the test sheets.
2.6.1 Responsibilities
The person who performs the tests (Tester) is responsible for the execution of the
tests. The tester confirms with his/her initials that the test is performed correctly.
A second person, (Witness) checks if the test was correctly performed and that the
result was in accordance with the acceptance criteria and if not, that a deviation
report is filled in.
2.6.2 Good Testing Practice

A (archive resistance) blue pen shall be used for the SAT tests, for approvals and for
the corrections in the attached design documents (such as Tank Drawing).
Correction fluid and other correction techniques that obscure the original entry shall
not be used.
Spelling mistakes and other changes shall be corrected as follows:
Ex: Installation 20/01/04 Initials
Deviations are recorded and traceable. Fields in a test, which is not filled out, shall be
clearly marked as N/A (not applicable)
Attachments such as Drawing and MOC check lists shall be marked with the name of
the SAT test and date and initials of the tester. This shall be written on all attached
page
Ex) Attachment to test FAT 2.1.1 Components 20/01/04 Initials
When the SAT is performed and completed, all documents associated with the SAT
shall be reviewed for correctness and completeness before the SAT Report section is
filled in.
Client Name Bayer
2.6.3 How to fill in the tests / inspections
Name of Test
Test procedure
Required document(s) / equipment
Acceptance criteria
1)
Pass /Fail + Deviation no
2)
Comment
3)
Tester, Date / Initials
4)
Witness, Date /initials
5)
For a description of the different sections of each test script please see below:
1) The acceptance criteria are specified in this square and if values are to be recorded there
will also be an “Actual value” result table provided. The tester shall Fill in the actual value
observed and then indicate a “Pass” or “Fail”. in the square provided.
Description Required value Actual value Result (Pass /Fail)

Ex) Temperature at > 80°C
TT270.6.3
2) If the acceptance criteria are fulfilled, “Pass” is written in the square. If not, “Fail” and
deviation number(s) are written, and a deviation report is filled in. (See deviation Report)
3) Comment: This field is used to provide additional information on how the test was
executed, any anomalies identified, additional explanatory information and additional
details if required to explain what occurred in a particular deviation, the tester should
include the Date of the execution of the test / inspection and initials of the tester.
4) The witness should include the date of the execution of the test /inspection and initials of
witness.
Client Name Bayer
2.6.4 Deviation handling
A Deviation report regarding SAT is filled in, if the result of a test is not according to
the acceptance criteria. It could be necessary, to write more than one deviation report
per test. In this case all deviation numbers have to be filled in the test sheet.
2.7 Acceptance criteria
The acceptance criteria for each Site Acceptance Test are specified in the test sheets.
2.8 SAT Result
The result of the SAT will be concluded in the SAT Report section.
Client Name Bayer
3.0 Tests
Company Name Initials
XXXXXXXXX
XXXXXXXXX
Exergy LLC
Exergy LLC
Attachments to this Site acceptance test (To be filled in on the day for SAT start)
P & ID No. And Revision No.
Components List, Revision No.
Control Panel Wiring Diagram, Revision No.

Client Name Bayer
3.1 Mechanical & Documentation Inspections
Name of test
3.1.1 FAT Closure
Test procedure
Check if the retests specified in the FAT Report are performed, and signed in the FAT test sheets.
If not, perform those tests now and write “Pass” or “Fail” for the corresponding test in the FAT
document.
All the deviations should be closed before start of SAT.
The FAT Report.
Acceptance criteria
All the Factory Acceptance Tests shall have been executed.
Pass / Fail + Deviation no’s
Comment
Witness, Date / Initials

Client Name Bayer
Name of test
3.1.2 Verification of components as per P & ID
Test procedure
Check that the Point of Use Cooler is built according to the P & ID and that all
equipment/components are marked with the correct Tag Numbers as shown on the P & ID.
Write, “Pass” at the valve /instrument /component on the P & ID if both criteria are fulfilled. If not
write “Fail” and the deviation number on the drawing.
Corrections shall be written with an archive safe pen on the P & ID.
The tester, witness shall Sign & date the P & ID marked up for this test.
Attach the marked up P & ID to this document.
P & ID
Acceptance criteria
All valves, instruments and components shall be located according to the P & ID and be marked
with the correct Tag Number.
Comment

Client Name Bayer
Name of test
3.1.3 Verification of Electricals
Test procedure
Check that the Control panel is built according to the circuit diagram and that the items are marked
with the correct ferrule / tag numbers.
Write “Pass” at the valve/instrument /component on the circuit diagrams if both criteria are
fulfilled. If not, write “Fail” and the deviation number in the drawing.
Sign & date the circuit diagram.
Attach the circuit diagram used to verify the actual system (Electrical connections, Wiring) showing
the verification results to his document.
Circuit Diagram
Acceptance criteria
All the items shall be located according to the circuit and be marked with the correct Ferrule/Tag
numbers.
Comment

Client Name Bayer
Name of test
3.1.4 Verification of Component specifications
Test procedure
Check that Valves, Instruments and Components installed are in accordance with their description
and specification as mentioned in the List /design qualification.
Write, “Pass” at the Valve /Instrument /Component in the list, if the item is in compliance with the
specifications. If not write “Fail” and the deviation number in the list.
Corrections shall be written with an archive safe pen in the component list.
The Tester, Witness shall Sign & date in the bottom of each page of the marked up component list.
Attach the marked up Component List to this document.
Component List /Design Qualification
Acceptance criteria
All Valves, Instruments and Components shall be in the accordance with their description and
specifications in the Component List /Design Qualification.
Comment

Client Name Bayer
Name of test
3.1.5 Review of Test Certificates & Test Reports
Test procedure
Check that test certificates / Test Reports for components/ piping /fittings, and other Inspection
/test Reports are available as per the component list.
Write, “Pass” at the Valve /Instrument /Component in the list, if the required certificate is present.
If not write “Fail” and the deviation number.
Sign & date in the bottom of each page.
Attach the used component list to this document.
Needed document(s) / equipment
Certificates and the Component List.
Acceptance criteria
Certificates shall be present according to specifications in the Component list.
Comment

Client Name Bayer
Name of test
3.1.6 Check for availability of Manuals / Data
Test procedure
Check that Instruments/Component manual are present for instruments from the supplier as per
the component list.
Write, “Pass” at the Instrument /Component in the list, if the required certificate is present. If not
write “Fail” and the deviation number.
Sign & date in the bottom of each page.
Attach the used component list to this document.
Manual and the Component List.
Acceptance criteria
Certificates shall be present according to specifications in the Component list.
Comment

Client Name Bayer
3.2 System Acceptance Test
Name of test
3.2.1 To Check Functional Logic & Alarm
Test procedure
Test Procedure should be as per the Interlock and Alarm list of Design qualification, to challenge
each & every alarm provided in the system.
All the alarm will be checked during SAT.
Interlock and Alarm list
Acceptance criteria
All alarm shall be performed as per Interlock and Alarm list.

Comment

Client Name Bayer
Name of test
3.2.2 To Check I/O ‘s
Test procedure
Test Procedure should be to check each & every Digital & Analogue Input & Output of PLC, as per
the I/O List mentioned in design qualification.
I/O List
Acceptance criteria
All Inputs & Outputs shall be performed as per I/O List.
Comment

Client Name Bayer
3.3 Operation Test
Name of test
3.3.1 Leak Test
Test procedure
Put the Point of Use Cooler into “Operation mode” by drawing product water from any one user
point.
During operation, the operating pressure is maintained for product water circuit as well as cooling
water circuit.
 Let the Point of Use Cooler run for 15 mins.

 Check the tri-clover connections and components for leak test by visual inspection.
 If leakage is found, mark the leaking connection and/or components position on P&ID &
rectify the leak.
N/A
Acceptance criteria
No leaks shall be observed in the Point of Use Cooler.
Comment

Client Name Bayer
Name of test
3.3.2 Check for System Operating parameters
Test procedure
 Operate the Point of Use Cooler by drawing water from any sampling point.
 Fill in the log sheet and note the flow & temperature of product water exiting from
sampling point.

Design Qualification
Acceptance criteria
Flow and temperature of product water exiting from sampling point shall meet the required
parameters mentioned in design qualification.
Comment

Client Name Bayer
4.0 SAT Report
4.1 Purpose of the Report
To conclude the performed Site Acceptance Test of Point of use Cooler.
4.2 Deviations
The deviations shall be measured until the time for SAT.
Deviation summary
Total amount of attached deviations:

Client Name Bayer
Deviation list:
Description Noted by: Completed by

Deviation No.
(Date / Sign) ( Date / Sign)
Client Name Bayer
4.3 Retests
All tests that for some reason were not executed shall be performed after completion.
Test No. Test Name Test

completed
(Yes / No)
Mechanical & Documentation Inspections
3.1.1 FAT Closure
3.1.2 Verification of components as per P&ID
3.1.3 Verification of Electricals
3.1.4 Verification of Component specifications
3.1.5 Review of Test Certificates and Test Reports
3.1.6 Check for availability of Manuals & data
System Acceptance tests
3.2.1 TO check functional logic and alarm
3.2.2 TO check I / O list
Operation Tests
3.3.1 Leak Tests
3.3.2 Check for System Operating parameters.
Client Name Bayer
4.4 Final approval
To be signed by the SAT participants. If the customer has chosen not to attend the SAT,
HYDROPURE SYSTEMS will decide about the project handover.
POINT OF USE COOLER is validated and handed over to client
Name & Designation Company Sign & Date
EXERGY LLC
EXERGY LLC
CUSTOMER
CUSTOMER

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Site Acceptance Test (SAT)

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SITE ACCEPTANCE TEST

Client Name Bayer

Vendor’s Name Exergy LLC / Hydropure Systems

Project Name Bayer Shawnee R&D

Issue Date October 31, 2014

R-0 For approval

1.0 APPROVAL .......................................................................................................... 4

Department Name Designation Signature Date

2.0 SAT Plan

 Mechanical & Documentation Inspections

2.3 Reference Documents

2.4 Purpose of the Tests

2.5 Object description

Product : Point of Use Cooler

2.6 SAT Performance

2.6.2 Good Testing Practice

Ex: Installation 20/01/04 Initials

Ex) Attachment to test FAT 2.1.1 Components 20/01/04 Initials

2.6.3 How to fill in the tests / inspections

Required document(s) / equipment

Description Required value Actual value Result (Pass /Fail)

2.6.4 Deviation handling

2.7 Acceptance criteria

2.8 SAT Result

Company Name Initials

P & ID No. And Revision No.

Components List, Revision No.

Control Panel Wiring Diagram, Revision No.

3.1 Mechanical & Documentation Inspections

3.1.1 FAT Closure

Required document(s) / equipment

The FAT Report.

All the Factory Acceptance Tests shall have been executed.

Pass / Fail + Deviation no’s

Tester, Date / Initials

Witness, Date / Initials

3.1.2 Verification of components as per P & ID

Attach the marked up P & ID to this document.

Required document(s) / equipment

Pass / Fail + Deviation no’s

Tester, Date / Initials

Witness, Date / Initials

3.1.3 Verification of Electricals

Sign & date the circuit diagram.

Required document(s) / equipment

Pass / Fail + Deviation no’s

Tester, Date / Initials

Witness, Date / Initials

3.1.4 Verification of Component specifications

Attach the marked up Component List to this document.

Required document(s) / equipment

Component List /Design Qualification

Pass / Fail + Deviation no’s

Tester, Date / Initials

Witness, Date / Initials

3.1.5 Review of Test Certificates & Test Reports

Attach the used component list to this document.

Needed document(s) / equipment

Certificates and the Component List.

Certificates shall be present according to specifications in the Component list.

Pass / Fail + Deviation no’s

Tester, Date / Initials

Witness, Date / Initials

3.1.6 Check for availability of Manuals / Data