5.3.

2 Test procedure

The testing process can be divided into system performance, project scope, and
application. See Appendix A for checklists for FAT.

5.3.2.1 System performance checklists:

- start-up test;

- general system functions, including equipment redundancy and diagnostics.

5.3.2.2 Project Scope Checklists:

- verification of documentation;

- inventory of HW and SW;

- checking the mechanical part;

- checking the wiring and contacts.

5.3.2.3 Reference links

The documents listed below serve as the basis for testing functionality:

- diagrams of pipelines and instrumentation;

- functional plan;

- management description;

- cause-and-effect relationships, lists of blocks;

- functional logic circuits;

- integrated management schemes;

- interface documentation;

- information about color coding (colors of technological streams, block states, etc.);

- description of equipment assemblies and alarm principles;

- a description of the distribution of equipment units between operator workstations;

 - a description of the basic principles of management (access using graphic displays,

shared screens or faceplates);

- description of archived data.

The filled in signs are marked, and the received documents are considered the FAT
protocol.

5.3.3 Application verification procedures

5.3.3.1 Checking HMI displays

Before testing the control loop, check the static parts of the HMI displays.

The following (static) display functions need to be checked:

- symbols for designating vessels, technological lines, valves, sensors, motors, pumps,
etc .;

- the colors of the designation of static positions, for example, manual valves,
technological lines, etc.;

- directions and trajectories of technological streams, i.e. arrows of the direction of

technological lines;

- correctness of communication in control schemes with range selection;

- hierarchy and connection of displays;

- dynamic changes of colors, image elements and data points.

5.3.3.2 Checking characteristics

Prior to posting the FAT, a master document must be defined to ensure that all
characteristics are checked. It is preferable to use the instrumentation designation as the main
document, including all DCS related features and all subsystems included in the DCS (ESD,
PLC, on-board controllers, analyzer subsystems, etc.).

Checking the signs is carried out as follows.

Check bezels (functionality, service messages, range, units, etc.);

- communication with the level of input / output;

 - the corresponding screen for collective use;

- relevant trends.

Verify that the graphical display of the feature coordinates for the corresponding location
is occurring and that the colors of dynamic objects such as valves, motors, bar charts, etc. are
changing appropriately.

Checking the distribution of alarms: sorting criteria (priority, equipment zone, etc.).

Verify user login for operation and management.

5.3.3.3 Testing complex functions and interlocks

Testing of complex functions and interlocks is carried out after checking the corresponding
signs.

5.3.3.4 Additional functions (messaging)

Determined during the project.

5.3.3.5 Subsystem communication test

Signal simulation is carried out in accordance with the selected scenario.

The relevant functions are checked in accordance with the requirements of the feature
check.

In addition to testing the application, the following system characteristics are verified:

- crash recovery;

- reservation;

- alternative modes of operation.

5.3.3.6 Checking System Functions

In addition to testing the application, the following system characteristics are verified:

- crash recovery;

- reservation;

- strategy and levels of entry into the system;

 - strategy for handling and acknowledging alarms;

- guaranteed system performance (update rate, etc.).

     5.4 Elimination of Factory Test Notices (FAT)

Elimination of comments and subsequent re-checks are carried out during the FAT. If this
is not possible, such work is carried out after completion of the FAT by mutual agreement and
includes:

- determination of work to eliminate comments;

- action plan / timeline;

- performance of work to eliminate comments;

- re-check;

- end notification.

     5.5 Annex A Factory Acceptance Test (FAT) Documentation

a) Printing and signing of plans for tested functions;

b) the date and signature of the remaining documents drawn up during the FAT;

c) examining the list of comments;

d) preparation of HW and SW test documentation, preparation of backups of complete

system and application SW;

e) documentation of system reserve and loads;

f) providing a list and color copies of all graphic displays.

     6 On-site acceptance test (SAT)

     6.1 General

SAT is carried out after delivery / installation of the system at the buyer's site of operation.

The purpose of the SAT is to confirm the functionality of the system after delivery and
installation.

 Prior to testing, the appropriate HW / SW components must be delivered to the site and
properly installed. Before testing and during installation of the DCS / PLC, carry out the
following work:

- installation of equipment (controllers, input / output boards, cross-cabinets, operator /

design stations);

- power supply to the appropriate equipment under test;

- installation of an earthing system for the relevant EUT;

- installation of network communication facilities (for example, hubs, switches, fiber optic
cables, the Internet).

A checklist of activities to be performed during the SAT is given in Appendix B.

     6.2 Site Acceptance Test (SAT) Procedure

The test program (activities and schedule) is agreed between the buyer and the supplier.
The program includes, among others, the following activities:

Item Name
number

1 Kick-off meeting (review of documentation, scheduling, etc.)

2 Verification of supplier documentation

3 Inventory HW and SW

4 Mechanical check (earthing system, power supplies, network connections, etc.)

5 Start-up / diagnostic check (power up, start-up / commissioning of controllers,

diagnostics)

6 Loading SW

     

     7 Object Integration Testing (SIT)

     7.1 General

SITs are conducted by the purchaser after the successful completion of the SAT for each
system.

 The goal of SIT is to test the integration of two or more independent systems to achieve
the functionality envisioned by the basic management principles of a project. For example,
SITs can and should be conducted when integrating the following types of systems:

- packaging units with their own DCS / PLC controllers or unit controllers;

- analyzer systems interacting with DCS / PLC using non-standard input / output signals;

- emergency shutdown systems;

- combining DCS / PLC from several manufacturers;

- Combining DCS with a higher-level factory network;

- combining the two systems with SIT.

SITs must ensure that both systems work together to achieve the results envisaged by the
management principles. SITs include checking the communication and interoperability
between the automation system and subsystems to ensure proper and sufficient performance
of functions.

A checklist of activities to be performed during the SIT is given in Appendix C.

     7.2 Site Integration Testing (SIT) Program

The test program (activities and time schedule) is agreed between the buyer and the
supplier. The program includes, among others, the following works:

Item Name
number

1 Kick-off meeting (reviewing documentation, scheduling, etc.)

2 Verification of supplier documentation

3 Mechanical inspection (communication between systems)

4 Diagnostics (checking communication between systems, baud rates, etc.)

5 Load SW (if needed)

     

Appendix A

(informative)

     

Factory Acceptance Test (FAT) Checklists