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FOUNDATION™ Fieldbus: Factory Acceptance Test and Device Commissioning
FOUNDATION™ Fieldbus: Factory Acceptance Test and Device Commissioning
Taipei, Taiwan
27th July 2010
Agenda
Factory Acceptance Test. Brief Introduction
Scope of Test. Hardware Commissioning. Functionality Test. Redundancy Host Test. Segment Check Test. Cable Check and Test.
Introduction
1. Traditionally, Factory Acceptance Test (FAT) is testing the factory acceptance level of the host system, field devices and subsystems. 2. FAT procedure includes staging test plan, guidelines, specifications and methodology prepared by DCS vendor and client as defined in the project conceptual design and detail engineering documentation. 3. Some of these includes and not limiting to the following: - Fieldbus power requirements. - Fieldbus networks/segments. - Fieldbus communication. - Host (hardware and software) integration. - Loop checks and database verification. - HMI graphics checks. - Fieldbus device inspection (data sheets). - Etc, etc.
Scope of Test
1. Appropriate test equipment (calibrated to international standards) for simulation of process variables or to measure output values. 2. In certain cases software simulation is also used for soft loop integrity checks. 3. Other tests includes and not limiting to the following: - Hardware commissioning. - Functionality test. - Calibration check. - Redundancy host switch-over test. - Segment check. - Cable check and test.
Hardware Commissioning
1. System hardware audit physical, cable dressing, point to point terminations, fieldbus terminators, tagging, name plates, identification labels, etc. 2. System grounding Host cabinet safety and isolation grounding. 3. System power supply UPS power, 24Vdc. Fieldbus power conditioner. Fieldbus power supply test specification.
FF-831
Functionality Test
1. Fieldbus devices plug and play interconnectivity to host systems. Fieldbus device should be self discover on the segment to which it is connected. 2. Commissioning and matching of field devices, download configuration. 3. Verification and testing of device function blocks, actual device operation from the controller or on the wire. 4. Simulation of process inputs using test equipment OR through use of software simulation at the input or output function block.
Trunk
Spur SIM ACT
AI PID
SIM
AO
3. Disconnect host, alarms will alert. Fieldbus devices remains visible in segments. No loss of information, signal bumps, etc as per specifications. 4. Repeat for other host. 5. Integration test of host with Controller as defined in project documentation.
FB Power Conditioner
FF-831
FIM4
2. Spare capacity for expansion, observe specification on hosting devices per segment and check bandwidth using Link active scheduler or equivalent.
H1 Network
2. Before trunk and spur cables are connected to any Fieldbus devices or termination block, cable insulation and capacitance test are required. 3. Follow FF engineering guide AG-181 for installation, commissioning of fieldbus segments, measurements of resistance, capacitance of fieldbus cables.
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8. Optional bus monitor capture and scope wave form capture for segment analysis.
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Preparation
1. Prior to start with device commissioning, all FF devices shall be loaded with minimum (pre-tagged devices), each device is uniquely identified: 1. Device ID.
- Device vendor identification, model type, etc.
3. Device Address
- Unique numeric address on the segment.
2. All devices arrive on site pre-configured, pass the inter-operability test at host testing and qualification center using device vendor DD, EDDL or DTM files. 3. Completed the FAT testing.
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Thank You
www.fieldbus.org
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