FAT (Factory Acceptance Test) is carried out in order to demonstrate that the system and its components function properly, that manufacturing, assembly, configuration and software generation are done correctly and that system performance is in compliance with the approved functional specifications and relevant documents.
The same should be carried out for DCS also,
The basic requirements of FAT:
The test should be carried out with completely assembled system and complete I&C software performing all function expected out while in actual service.
Both computer code and technology programs to be installed and worked on the system until fat
- General visual check and bill of materials check
- Construction check as per over all general arrangement drawings
- Dimensional check
- Labelling , terminal arrangement and equipment identification check
- Power supply voltage level check and power leeds -on check
- Cooling fan operation check
- Grounding network check
The fat treatment shall be prepared by the supplier and sent well in advance before the beginning of the fat for approval by the purchaser / consultant.
FAT procedure at control system:
Terminal arrangement and wiring check
Power supply under voltage and over voltage check
Verification of jumper settings
Verification of healthiness of individual processors
Verification of operator interface displays
Verification of control functions: Start-up control, Acceleration control, Speed/Load control, Temperature control, Fired shutdown, Emergency shutdown
Verify protection systems: over speed, over temperature, vibration, master protection, flame detection.
Redundancy test for controllers
Communication interface to DCS verification
FAT for Field instrument:
- Pressure indicators
Calibration Hydro test (1.5 times max. pr.)
Calibration test / Hydro test / Contact rating test / Accuracy test / Repeatability
- Differential Pressure Indicators
Calibration test / Hydro test / Leak test / Over range test / Accuracy test / Repeatability test.
- Differential Pressure Switches
Calibration test / Hydro test / Contact rating test / Leak test / Accuracy test / Repeatability test.
Calibration / Material test / Accuracy test / Bore concentricity: + 5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.)
- Temperature switch
Calibration / Material test / Accuracy test / Bore concentricity: 1.5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.) / Contact rating test.
Resistance temperature detector assembly. Calibration / Material test / Bore concentricity test / Insulation test (< 500 M at 500V DC) as per ISA, Hydro test for TW. Bore concentricity: + 5% of wall thickness, Accuracy test.
- Thermocouple assembly
Calibration / Material test, Insulation test (> 500 at 500 V, DC) as per ISA, Hydro static test (1.5 times max. pr.), Bore concentricity: + 5% of wall thickness.
- Thermo wells
Material test / Bore concentricity: + 5% of wall thickness / Hydrostatic test for TW (1.5 times max. pr.)
- Level Gauges
Hydrostatic test / Material test / Seat leakage test / Ball check test.
- Level switches (Magnetic)
Material test / Contact rating test / Hydro test / Calibration test.
- Flow Switch
Material test / Hydro static test (1.5 times max. pr.) / function test.
Calibration test / Material test / Hydrostatic test (1.5 times max. pr.)
- Flow element
100% Radiography test / Hydro test / Calibration test, IBR Certificate. Calibration test for flow element shall be witnessed by Purchaser/Consultant.
Electro Pneumatic Converters
Calibration test / Accuracy test
- Solenoid valves
Hydro test / Seat leakage test / CV test / Coil insulation test
- Air filter regulators
Calibration test / Accuracy test
- Junction Boxes
Test for degree of protection / Material test
- Tests for terminal blocks
Test for moulding for flame resistant, Non-hygroscopic and Decarbonised / Insulation test between terminals / Insulation between terminal block and frame.
- Thermocouple extension cable
Thermo-elf characteristic / Continuity test / Measurement on capacitance, inductance and loop resistance / Insulation resistance / High voltage test as per latest IS / Tensile and elongation test / Oxygen index test / Any other test applicable.
- Mass flow meter
Performance test / Calibration test / Hydrostatic test.
Hydrostatic test / Material test / Seat leakage test / IBR Certificate
- Local Panels
Visual inspection, wiring & continuity check, h.v. and i.r. tests on panels, checking of bill of materials, functional tests.